Senior Stress Analysis Engineer

Evolito Limited; Bicester; On-site; GBP 85,000 - 100,000; Full time

Job summary

Evolito Limited is seeking a Senior Stress Analysis Engineer to develop and apply stress and vibration analyses for electric propulsion units (EPUs), delivering robust designs for motors, controllers, gearboxes, and heat exchangers.

You will drive DFMEAs, support testing, and mentor junior stress engineers while engaging with suppliers and customers to resolve design challenges and ensure manufacturability as Evolito scales in the UK.

Qualifications

• Degree level qualification in Mechanical, Aerospace Electromechanical Engineering or similar.
• Experience in a design and development environment.
• Practical knowledge in electric machines or rotational/complex components.

Responsibilities

• Perform Finite Element Analysis (FEA) and hand calculations for structural assessment of EPU assemblies.
• Perform vibration analysis to evaluate dynamic performance.
• Conduct fatigue evaluations based on FEA results.
• Use FEA optimisation tools to improve strength, mass, and manufacturability.
• Drive and manage test work to validate analyses and gather data.
• Collaborate with suppliers and customers to resolve design issues and find optimal solutions.

Skills

FEA & hand calculations

Vibration analysis

Fatigue evaluation

Design optimisation

Mater ials properties knowledge

Client & supplier communication

Travel readiness

Education

Mechanical/Aerospace Engineering degree

Job description

Evolito's mission is to accelerate the adoption of electric propulsion in aerospace applications in support of a net-zero world. We will help to revolutionise personal mobility and transform our towns and cities with clean, noise-free air transportation.

Evolito develops and manufactures class-leading, lightweight, high-power, and high-torque-density electric propulsion systems for a range of aerospace markets, including EVTOL, Unmanned Aerial Vehicles and General Aviation.

As well as ultra-high performance, low-weight electric motors and controllers, Evolito specialises in high-integrity, bespoke battery systems for the aerospace and defence markets.

The team is scaling rapidly and has ambitious growth plans over the next twelve to eighteen months.

As part of our current high-growth phase, we are looking for a Senior Stress Analysis Engineer to use and develop appropriate stress and vibration analyses techniques to deliver robust designs for electric propulsion architecture including the motor, controller, gearbox, pump and heat exchanger. Reporting to our CAE Project Lead, you will also develop new concepts to optimise the electric propulsion unit performance and durability that are suitable for manufacture, whilst also driving the necessary physical testing to verify the analyses and provide data to support conclusions.

Key responsibilities will include:

• Undertake Finite Element Analysis (FEA) and appropriate hand calculations for the structural assessment of electric propulsion unit (EPU) assemblies and sub-assemblies
• Assess results against customer specifications and draw sound conclusions
• Undertake vibration analysis to assess the dynamic performance of the given design
• Carry out a fatigue evaluation based on FEA results
• Use FEA optimisation tools to derive solutions based on strength, mass reduction and manufacturability
• Support and develop junior Stress engineers
• Develop ideas and design solutions to practical challenges arising from new product design
• Propose material and process selections suitable for loading conditions and mass volume production
• Drive and manage test work that will validate the analysis
• Investigate and draw conclusions on root cause analysis of products
• Liaise with key suppliers and customers on design and development issues, resolve to the optimal solution and understand the compromises
• Support DFMEAs, other quality techniques and complete actions required to mitigate risks
• Write specifications and reports as required through the product lifecycle, utilising a structured approach to problem-solving techniques.

Skills and experience required:

• A degree level qualification in Mechanical, Aerospace Electromechanical Engineering or similar
• Previous proven experience working within a design and development environment
• Practical knowledge in the design, use, and application of electric machines or rotational/complex components
• Strong structural and design optimisation skills, with a focus on strength, weight and manufacturability
• Strong structural and design optimisation skills, with a focus on strength, weight and manufacturability
• Good understanding of aerospace materials and associated mechanical properties and processing
• Self-sufficient and able to work with minimal managerial input
• Confident with customers and suppliers; able to interpret requirements and understand issues
• Passionate about delivering high-quality outcomes and making a positive impact
• Takes ownership and accountability for commitments and results
• Builds trust through integrity, openness and professionalism
• Works collaboratively and contributes positively to team success
• Communicates effectively with a wide range of stakeholders
• Adaptable, proactive and comfortable working in a growing business
• Demonstrates curiosity, initiative and a commitment to continuous improvement
• Willingness to travel as required

Desirable:

• Experience in aerospace and certification programs
• Experience with rotordynamics and vibration (forced response) analyses
• Composite materials evaluation techniques, both simulation and physical

Are you Evolito?

We're driven by a shared passion for engineering excellence and sustainable mobility. Our unique technology enables us to fast-track the adoption of electric propulsion in aerospace. By accelerating the growth of electric propulsion, we will help revolutionise personal mobility and transform our towns and cities with clean, noise-free electric air transportation. As part of our growth, we are looking for passionate, talented people join the team and help transform the way we travel.