Stress Analysis Engineer - Propulsion

z21 Ventures; Milton Keynes; On-site; GBP 55,000 - 75,000; Full time

Job summary

Greenjets is seeking a Propulsion Stress Analysis & Mechanical Integrity Engineer to ensure structural integrity, durability and safety of rotating and static components within small gas turbines and electric ducted fan propulsion systems.

This role blends analytical modelling, detailed finite element analysis (FEA) and interpretation of test data to shape mechanical integrity requirements and validate designs in a fast-moving SME environment.

Qualifications

• Degree in Mechanical, Aerospace, Materials Engineering or related discipline.
• Strong foundation in solid mechanics, fatigue/fracture mechanics, vibration and material behaviour.
• Proficiency with major FEA tools (ANSYS, ABAQUS, NASTRAN, etc.).
• Experience with rotating machinery integrity (turbines/fans/compressors).
• Familiarity with containment, overspeed criteria, lifing and safety margins.
• CAD interaction experience (SolidWorks, NX, CATIA or similar).
• Experience with fatigue life prediction tools (nCode, FEMFAT or equivalent).
• Hands-on attitude, testing, troubleshooting and multidisciplinary teamwork.
• Strong communication skills capable of explaining technical concepts to engineers and stakeholders.

Responsibilities

• Perform stress, strain and deformation assessments for rotors, stators, shafts, casings, frames, mounts and ducts.
• Conduct static, dynamic, fatigue, creep, buckling and vibration analyses; assess rotor critical speeds and Campbell diagrams.
• Apply safety margins and failure criteria aligned with turbomachinery integrity principles.
• Build and run detailed 3D FEA models (ANSYS, ABAQUS, NASTRAN or equivalent).
• Execute non-linear, transient and thermo‑mechanical simulations and validate with test data.
• Assess mechanical behaviour of high‑speed rotors in gas turbines and EDF systems.
• Collaborate with thermal engineers to evaluate thermal gradients and material response.
• Provide structural load cases, design constraints and feedback to design teams.
• Draft structural substantiation documents and contribute to hazard analyses.

Skills

Solid mechanics

Fatigue/fracture mechanics

Vibration analysis

Material behavior

FEA software

Rotating machinery experience

Containment/overspeed concepts

Education

Degree in Mechanical, Aerospace, or Materials Engineering

Tools

ANSYS

ABAQUS

NASTRAN

SolidWorks

NX

CATIA

nCode

FEMFAT

Job description

About Us

Greenjets is an innovative engineering company developing high-performance propulsion systems for the aviation market. Our work spans research and development, engine production, aircraft systems, technical integration and flight testing. We are committed to delivering high-grade engineering and best-in-class propulsion for unmanned aircraft.

We do things differently. We move fast, we experiment and we adopt technologies that push beyond the current state of the art. Our aim is to go further, faster and more efficiently, while keeping costs competitive. All our propulsion systems are designed, developed and manufactured in the UK. We focus on high quality, reliable and cost effective products supported by a robust, secure and ethical supply chain.

About the Job

Greenjets is seeking a Propulsion Stress Analysis & Mechanical Integrity Engineer to ensure the structural integrity, durability, and safety of rotating and static components within small gas turbines and electric ducted fan propulsion systems.

This role is central to the product development lifecycle, combining analytical modelling, detailed finite element analysis (FEA), structural substantiation, and interpretation of test data. You’ll work closely with multidisciplinary engineering teams to shape mechanical integrity requirements and validate designs in a fast-moving SME environment.

What You'll Do

Structural & Mechanical Integrity

• Perform stress, strain and deformation assessments for rotors, stators, shafts, casings, frames, mounts and ducts.
• Conduct static, dynamic, fatigue, creep, buckling and vibration analyses, including rotor critical speeds and Campbell diagrams.
• Apply safety margins and failure criteria aligned with turbomachinery integrity principles.

Finite Element Analysis

• Build and run detailed 3D FEA models (using ANSYS, ABAQUS, NASTRAN or equivalent).
• Execute non-linear, transient and thermo‑mechanical simulations and validate models against test data.

Rotating Machinery Integrity

• Assess mechanical behaviour of high‑speed rotors in gas turbines and EDF systems.
• Define overspeed test cases and containment requirements, considering uncontained rotor risk scenarios.

Thermal & Thermo‑Mechanical

• Collaborate with thermal and aerothermal engineers to evaluate thermal gradients, distortion and material response.

Support Design & Development

• Provide structural load cases, design constraints, stiffness criteria and feedback to design teams.
• Support design for manufacturability, including additive manufacturing considerations.

Test and Validation

• Define instrumentation for structural and vibratory testing.
• Support engine and spin rig test campaigns and analyse strain gauge and vibration data.

Certification & Safety

• Draft structural substantiation documents, compliance evidence and contribute to hazard analyses.

Desirable Qualifications, Experience & Attributes

• Degree in Mechanical, Aerospace, Materials Engineering, or related discipline.
• Strong foundation in solid mechanics, fatigue/fracture mechanics, vibration and material behaviour.
• Proficiency with major FEA tools (ANSYS, ABAQUS, NASTRAN, etc.).
• Experience with rotating machinery integrity (turbines/fans/compressors).
• Familiarity with mechanical integrity concepts such as containment, overspeed criteria, lifing and safety margins.
• CAD interaction experience (SolidWorks, NX, CATIA or similar).
• Experience with fatigue life prediction tools (nCode, FEMFAT or equivalent).
• Hands‑on attitude, comfortable with testing, troubleshooting and multidisciplinary teamwork.
• Strong communication skills capable of explaining technical concepts to engineers and stakeholders.

Desirable

• Experience with micro gas turbines, small turbofan/EDF rotors.
• Additive manufacturing materials and constraints exposure.
• Experience supporting structural certification or compliance documentation.