Senior Stress Engineer

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

Job summary

Safran Actuation Systems UK in Wolverhampton is seeking a Senior Stress Engineer to support design and development of hydraulic, mechanical, geared, and electro-mechanical actuation systems across the product lifecycle.

You will perform preliminary and detailed structural analyses, assess fatigue, margins of safety, and reliability, and produce clear technical reports for internal teams and customers. Collaborative and hands-on, you’ll influence robust aerospace solutions.

Qualifications

• Strong understanding of classical stress analysis methods.
• Excellent written and oral communication skills.
• Demonstrated problem-solving skills in structural analysis environments.

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 analysis to assess strength, durability and performance.
• Evaluate stress, fatigue life and failure modes of gears, splines, threads and bearings.
• Produce technical reports and recommendations for engineering decisions.
• Present analysis findings to internal stakeholders and customers.
• Collaborate with multidisciplinary teams across the product lifecycle.
• Contribute to product improvements in performance, reliability and manufacturability.
• Support manufacturing with root cause investigations and corrective actions.

Skills

Classical stress analysis

Structural analysis

Technical communication

Tools

FEA software

Job description

Safran is an international high-technology group operating in the fields of aerospace (propulsion, equipment and interiors), space and defense. Its mission is to contribute sustainably to a safer world, where air transport becomes ever more environmentally friendly, comfortable and accessible. Present on every continent, the Group employs 110,000 people and generated €31.3 billion in revenue in 2025. Safran holds, either independently or through partnerships, leading global or European positions in its markets.

Safran was ranked second in the Aerospace & Defense sector in TIME magazine's "World's Best Companies 2025" ranking.

Safran Electronics & Defense is an international company with more than 19,000 employees who bring together expertise and team spirit to design high-technology solutions for the aerospace, defense and space sectors. By combining human and technological intelligence, the company develops products and services for both civil and military customers, operating on land, at sea, in the air and in space.

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.

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.