Senior Stress Engineer

Aalto Haps Ltd.; Orpington; On-site; GBP 65,000 - 90,000; Full time

Benefits offered by this job

Performance Bonus

25 days annual leave

Private healthcare

Pension contributions

Income protection & Life assurance

EV & Car scheme

Employee assistance programme

Perkbox discounts

Job summary

AALTO, a global aerospace innovator based in the United Kingdom, seeks a Senior Stress Engineer to own structural analysis across the product lifecycle, from concept to production support. You will perform FEA and hand calculations, work with multidisciplinary teams, and advise on composites and materials testing to ensure safety and reliability of aircraft platforms.

This role offers hands-on manufacturing support, continuous improvement, and opportunities to advance Stratospace technologies

Qualifications

• Experience in structural stress analysis within the aviation or aerospace industry.
• Strong understanding of aircraft structural design principles and requirements verification.
• Experience performing both Finite Element Analysis (FEA) and classical hand calculations.
• Working knowledge of composite materials and composite structural analysis methodologies.
• Proficiency with industry-standard analysis tools such as ANSYS, Nastran, or equivalent software.

Responsibilities

• Lead structural analysis activities throughout the aircraft design and development process.
• Conduct material selection and structural concept trade studies during preliminary design phases.
• Develop and maintain structural design records using applicable historical data and analysis.
• Provide structural engineering support and decision-making for production and line maintenance activities.
• Collaborate with mechanical design engineers to develop detailed design solutions for new and existing aircraft platforms.
• Provide technical guidance and specialist advice to cross-functional product development teams.
• Support concept studies, design reviews, and the resolution of build-related engineering challenges.
• Plan and support structural and materials testing activities required for design validation and certification.
• Lead or contribute to engineering reviews for assigned work packages.
• Support production teams by investigating and resolving structural repairs, concessions, and deviation requests.
• Identify and implement continuous improvement opportunities to enhance product quality, performance, and manufacturing efficiency.
• Maintain and develop technical knowledge, skills, and professional competence within the discipline.

Skills

Structural stress analysis

Aircraft structural design

FEA

Hand calculations

Composite materials

ANSYS

Nastran

Engineering requirements

Problem solving

Multidisciplinary teamwork

Communication

Continuous improvement

Tools

ANSYS

Nastran

Job description

About The Role

This is an exciting opportunity for a Senior Stress Engineer to take ownership of structural analysis activities across the product lifecycle, from early concept studies through to production support and in‑service design improvements. You will play a key role in developing structural design solutions for current and future aircraft, working closely with multidisciplinary engineering teams to overcome complex design and programme challenges. The role combines analytical expertise, practical problem‑solving, and hands‑on support to manufacturing and maintenance teams, helping to ensure the continued safety, performance, and reliability of our aircraft.

Responsibilities

• Lead structural analysis activities throughout the aircraft design and development process.


• Conduct material selection and structural concept trade studies during preliminary design phases.


• Develop and maintain structural design records using applicable historical data and analysis.


• Provide structural engineering support and decision‑making for production and line maintenance activities.


• Collaborate with mechanical design engineers to develop detailed design solutions for new and existing aircraft platforms.


• Provide technical guidance and specialist advice to cross‑functional product development teams.


• Support concept studies, design reviews, and the resolution of build‑related engineering challenges.


• Plan and support structural and materials testing activities required for design validation and certification.


• Lead or contribute to engineering reviews for assigned work packages.


• Support production teams by investigating and resolving structural repairs, concessions, and deviation requests.


• Identify and implement continuous improvement opportunities to enhance product quality, performance, and manufacturing efficiency.


• Maintain and develop technical knowledge, skills, and professional competence within the discipline.

Skills and Knowledge Required

• Experience in structural stress analysis within the aviation or aerospace industry.


• Strong understanding of aircraft structural design principles and requirements verification.


• Experience performing both Finite Element Analysis (FEA) and classical hand calculations.


• Working knowledge of composite materials and composite structural analysis methodologies.


• Proficiency with industry‑standard analysis tools such as ANSYS, Nastran, or equivalent software.


• Ability to interpret engineering requirements and translate them into robust analytical solutions.


• Strong problem‑solving skills with the ability to support both design and production environments.


• Excellent communication and collaboration skills, with experience working in multidisciplinary engineering teams.


• Ability to review, challenge, and justify engineering decisions using sound technical reasoning.


• Commitment to continuous improvement, innovation, and engineering excellence.

About AALTO

AALTO, a global leader in Stratospace. Based in Farnborough, AALTO is an Airbus subsidiary that manufactures, operates, and delivers services with its solar‑powered, stratospheric platform: Zephyr. Zephyr's persistence enables continuous flight for months at a time. Its current flight‑time record of over 67 days in the stratosphere. From above 60,000+ ft, or 20 km above ground, AALTO can deliver several applications including direct‑to‑device connectivity and high‑resolution Earth observation. AALTO operates in a new operational layer between most of air traffic and low‑Earth orbit, Stratospace. This is where high‑altitude platforms led by Zephyr deliver services to commercial and government partners. We can help monitor environments, observe borders, track natural disasters and connect unconnected communities. Join us as we create a new domain of aerospace: Stratospace. You will be part of a highly‑skilled, innovative and passionate group of people – Team AALTO. Together, we can unlock experience in structural stress analysis within the aviation or aerospace industry.

Benefits

In addition to a competitive, market‑aligned salary, we offer a comprehensive benefits package designed to support your wellbeing, financial security, and work‑life balance:

• Performance BonusBenefit from our short-term incentive plan, recognising and rewarding individual and company success.


• Generous Annual LeaveEnjoy 25 days of annual leave, giving you the time to rest, recharge, and spend time on what matters most.


• Private HealthcareAccess private medical insurance, alongside dental and optical cashback schemes, helping you and your family stay healthy.


• Pension ContributionsPlan confidently for the future with our competitive personal pension scheme.


• Income Protection & Life AssuranceGain added peace of mind through income protection and life assurance cover, providing support when you need it most.


• Electric Vehicle & Car SchemeAccess our salary sacrifice vehicle scheme, offering a cost-effective way to drive the latest cars.


• Employee Assistance ProgrammeReceive confidential professional support whenever you need it through our dedicated employee assistance programme.


• Employee DiscountsEnjoy a wide range of discounts and offers through Perkbox, covering everything from shopping and travel to leisure activities and everyday essentials.

This is all part of our commitment to creating an environment where our people can thrive both professionally and personally.