Senior Stress Engineer

Safran; West Midlands; On-site; GBP 65,000 - 90,000; Full time

Benefits offered by this job

Competitive salary

Company performance bonus scheme

Pension scheme - up to 10% employer

Private medical insurance

Health cash plan

25 days annual leave + bank holidays

Flexible benefits programme

Structured training & progression

ERGs and community projects

Job summary

Safran Actuation Systems UK in Wolverhampton is seeking a Senior Stress Engineer to lead structural analysis across hydraulic and mechanical actuation systems. You will perform sizing, fatigue, and failure investigations using classical methods and FEA, delivering reports to support design decisions and customer requirements.

You will collaborate with multidisciplinary teams throughout the product lifecycle, drive robustness, reliability and manufacturability, and contribute to continuous

Qualifications

• Strong understanding of classical stress analysis methods.
• Excellent written and oral communication skills.
• Experience with structural analysis and failure investigations.

Responsibilities

• Perform preliminary sizing and structural analysis for actuation systems.
• Deliver stress analysis on hydraulic actuators, valve blocks, gearboxes and related systems.
• Apply classical and computational methods to assess strength, durability and performance.
• Evaluate fatigue life and failure modes of mechanical elements to ensure robust designs.
• Produce technical reports and present findings to stakeholders and customers.
• Collaborate with multidisciplinary teams across the product lifecycle.
• Support continuous product improvement and investigate root causes in production.

Skills

Classical stress analysis

Stress analysis reporting

Communication skills

Tools

FEA

Job description

Senior Stress Engineer

Wolverhampton

At Safran, excellence is a journey - and we'd love you to be a part of it. As a trusted global leader in aerospace, defence, and space, we are proud to be a company where diversity, innovation, and opportunity come together to shape a sustainable future where we can all succeed together through a shared vision.

About Safran Actuation Systems UK

Safran Actuation Systems UK is a world class centre for the design, manufacture and support of actuation and flight control solutions used across commercial, military and rotary platforms. With major sites in Wolverhampton and Banbury, our teams play a critical role in delivering innovative, reliable and safe systems that keep aircraft performing at their best.

We are seeking a skilled Senior Stress Engineer to support the design and development of advanced hydraulic, mechanical, geared, and electro-mechanical actuation systems. Working across the full product lifecycle, from concept and design through to testing, manufacturing, and production support, you will perform both preliminary and detailed structural analysis to ensure product performance, reliability, and compliance.

Using classical and computational analysis methods, you will assess structural integrity, fatigue, and failure modes while working closely with multidisciplinary teams and customers. This is an exciting opportunity to influence innovative aerospace solutions and solve complex engineering challenges in a collaborative environment.

What do we offer?

• Competitive salary
• Company performance bonus scheme
• Pension scheme - up to 10% employer contribution
• Private medical insurance
• Comprehensive health cash plan
• 25 days annual leave + bank holidays
• Flexible benefits programme (buy & sell holiday allowance, discounted gym memberships, Maternity/ adoption leave- up to 52 weeks, first 26 weeks at full pay, subsequent 26 at 50% (basic pay))
• Structured training & opportunities to progress
• Opportunity to join ERGs (employee resource groups), participate in community projects & much more!

Your role:

• Perform preliminary sizing and structural analysis to support the concept, design, and development of advanced actuation systems.
• Deliver stress analysis on a broad range of components, including hydraulic actuators, valve blocks, gearboxes, ball screw actuators, and associated mechanical systems.
• Apply both classical and computational analysis techniques to assess the strength, durability, and performance of critical components.
• Evaluate stress, strain, fatigue life, and failure modes of mechanical elements such as gears, splines, threads, lead/ball screws, and bearings to ensure robust and reliable designs.
• Produce clear, concise technical reports and recommendations to support engineering decisions and customer requirements. Present analysis findings and technical updates to internal stakeholders and external customers.
• Collaborate with multidisciplinary teams throughout the product lifecycle, supporting the development and maturation of new and existing products.
• Contribute to continuous product improvement by enhancing performance, reliability, and manufacturability.
• Support manufacturing and production activities through root cause investigations and the implementation of effective corrective actions.

Essential skills:

• Strong understanding of classical stress analysis methods.
• Excellent written and oral communication skills, capable of effectively communicating with diverse audiences.
• Demonstrated problem-solving skills in structural analysis environments, including experience in investigating complex failure investigations.

Desirable skills:

• Strong expertise in structural FEA, including linear, non-linear, contact, dynamic, vibration, and plasticity analysis.
• Proven ability to perform stress assessments and produce robust margins of safety with confidence.
• Excellent communication and stakeholder management skills, with the ability to present complex technical information clearly to customers and multidisciplinary teams.
• Highly collaborative, self-motivated, and capable of delivering high-quality results in a fast-paced engineering environment.
• Adaptable and organised, with strong planning, prioritisation, and problem-solving skills.
• Demonstrates the highest levels of professional integrity, accountability, and attention to detail.
• Comfortable working independently, managing changing priorities, and supporting production and business-critical challenges as they arise.