Lead Stress Analyst - Propulsion and Fluids

Firefly Aerospace; Cedar Park (TX); On-site; USD 120,000 - 190,000; Full time

Job summary

Firefly Aerospace is seeking a Lead Stress Analyst for Propulsion and Fluids within the Mechanical Engineering group. You will own structural integrity from design through qualification, leading complex analyses and defining methods for propulsion system components.

You will guide test correlation, mentor engineers, and collaborate across design, materials, and manufacturing teams to deliver robust, weight-efficient hardware for multiple product lines.

Qualifications

• B.S. in Aerospace, Mechanical, or a related engineering discipline.
• 5+ years of relevant experience in structural/stress analysis and qualification of aerospace hardware.
• Experience with fatigue, fracture mechanics, and damage tolerance methods for flight-critical hardware.
• Experience with thermal / thermo-mechanical stress analysis.
• Experience analyzing pressurized components such as lines, ducts, and bellows.

Responsibilities

• Lead stress analysis of propulsion and fluid system hardware, including thrust chambers, feedlines, manifolds, valves, and pressurized components
• Perform and review static, thermal, dynamic, and durability analyses to guide design decisions and meet life requirements
• Perform structural analysis using both finite element analysis (Ansys and/or Nastran) and classical hand calculations, and validate models against test data
• Define and improve analysis methods, standards, best practices, and material allowables for propulsion and fluid systems
• Generate interface loads and boundary conditions that drive sizing of downstream hardware
• Develop test requirements for qualification campaigns, correlate analysis models with test data, and support anomaly investigations and design improvements
• Collaborate with design, materials, manufacturing, and test engineers throughout the design lifecycle to drive manufacturable solutions
• Produce clear, well-documented analysis reports, provide technical guidance and mentorship to less-experienced engineers, and review internal and external analyses

Skills

Finite element analysis

Fatigue and fracture mechanics

Thermal/thermo-mechanical analysis

Structural mechanics fundamentals

Load path analysis

Education

Bachelor’s degree in Aerospace or Mechanical Engineering

MS or PhD in Aerospace or Mechanical Engineering (preferred)

Tools

Ansys

Nastran

NASGRO/AFGROW

Additive manufacturing structural analysis

Job description

Lead Stress Analyst - Propulsion and Fluids

ABOUT FIREFLY AEROSPACE

SUMMARY

As the Lead Stress Analyst for Propulsion & Fluid Systems in the Mechanical Engineering department, you will provide technical leadership for the structural analysis of propulsion and fluid system hardware. You will own the structural integrity of engine and fluid-system components from early design through qualification and flight across multiple product lines.

This is a technical leadership role. You will define analysis methods, drive the most complex and highest-risk analyses, set the technical direction for propulsion & fluid systems stress, and be a key voice in decisions on material allowables. You will provide technical guidance and mentorship to other analysts and review internal and external analyses. You will work closely with design, materials, manufacturing, and test engineers to deliver structurally robust, weight-efficient hardware that meets program and customer requirements. To be successful, you should be able to independently scope, execute, review, and defend structural analyses.

RESPONSIBILITES

Lead stress analysis of propulsion and fluid system hardware, including thrust chambers, feedlines, manifolds, valves, and pressurized components

Perform and review static, thermal, dynamic, and durability (fatigue, fracture, and damage tolerance) analyses to guide design decisions and ensure strength, stability, stiffness, and life requirements are met

Perform structural analysis using both finite element analysis (Ansys and/or Nastran) and classical hand calculations, and validate models against test data

Define and improve analysis methods, standards, best practices, and material allowables for propulsion and fluid systems

Generate interface loads and boundary conditions that drive sizing of downstream hardware

Develop test requirements for qualification campaigns, correlate analysis models with test data, and support anomaly investigations and design improvements

Collaborate with design, materials, manufacturing, and test engineers throughout the design lifecycle to drive manufacturable solutions

Produce clear, well-documented analysis reports, provide technical guidance and mentorship to less-experienced engineers, and review internal and external analyses

QUALIFICATIONS

Required

B.S. in Aerospace, Mechanical, or a related engineering discipline

5+ years of relevant experience in structural/stress analysis and qualification of aerospace or comparable high-performance hardware

Proficiency with finite element analysis (Ansys and/or Nastran) and classical hand analysis, with strong model validation and verification skills

Experience with fatigue, fracture mechanics, and damage tolerance methods for flight-critical hardware

Experience with thermal / thermo-mechanical stress analysis

Experience analyzing pressurized components such as lines, ducts, and bellows

Strong understanding of structural mechanics, load paths, and first principles related to structures and materials

Preferred

M.S. or PhD in Aerospace, Mechanical, or a related engineering field

Experience with analysis of liquid propulsion components, fluid systems, or rocket engine hardware

Experience with analysis of turbomachinery hardware

Experience with crack-growth / fracture software such as NASGRO or AFGROW

Experience with additive manufacturing structural analysis and material characterization

Experience correlating structural predictions with test or flight data