Senior Mechanical Engineer, Stress Analysis

Responsibilities

• Perform structural analysis (static, buckling, and modal) on airframe, gondola, and equipment mount structures using FEA tools (FEMAP/NX Nastran or equivalent)
• Develop and maintain finite element models, including mesh generation, load case setup, and post-processing of results
• Perform hand calculations to size structures, verify FEA results, and support quick-turn design trades
• Size and design structural components and assemblies, from concept sketches through detailed CAD
• Correlate analytical models against test data (static load tests, modal surveys, ground vibration testing)
• Support design trade studies weighing weight, strength, manufacturability, and cost
• Document analysis methodology, assumptions, and results in formal engineering reports
• Collaborate with Systems, Avionics, Soft Structures, Materials & Testing, and Manufacturing teams to integrate structural designs with the broader vehicle
• Support fabrication, assembly, and test of structural prototypes and hardware
• Investigate and resolve structural issues found during build, test, or field operations
• Perform joint analysis (bolted, bonded, and welded) to size fasteners, adhesives, and welds and substantiate joint margins

Qualifications

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a closely related field
• 5+ years of relevant experience in structural design and/or analysis
• Hands-on experience with FEA software (e.g., FEMAP, Nastran, ANSYS, or similar)
• Highly developed knowledge of structural analysis fundamentals: static strength, buckling, and modal/dynamic analysis
• Proficiency with 3D CAD (SolidWorks, NX, or similar)
• Experience with joint analysis (bolted, bonded, and/or welded joints)
• Scripting/programming experience (e.g., Python, MATLAB, or VBA) to automate analysis and modeling workflows
• Must be able to work on-site in Sunnyvale, California

Preferred Qualifications

• Experience with lighter-than-air, aerospace, or other weight-critical vehicle structures
• Experience correlating FEA models to physical test data
• Familiarity with composite structures (CFRP) design and analysis
• Experience with structural dynamics (modal testing, vibration analysis)
• Experience with fatigue analysis and life prediction
• Master's degree in Mechanical or Aerospace Engineering
• Experience in a fast-paced startup or low-volume prototype development environment
• Familiarity with GD&T and manufacturing drawing standards

What We Offer!

Compliance Requirements