Mechanical Stress Engineer II

Knight Aerospace Medical Systems LLC; San Antonio (TX); On-site; USD 80,000 - 90,000; Full time

Benefits offered by this job

Dental and Vision coverage

Medical Insurance

401(k) with Company Match

Paid Time Off

Paid Holidays

Long-Term Disability

409A Program

Job summary

Knight Aerospace Medical Systems LLC in San Antonio, TX is seeking an Aircraft Structural Analysis Engineer II – Stress & FEA to join our engineering team. You will perform detailed structural analyses, develop and validate finite element models, and support certification for modified aircraft components.

The role requires a bachelor’s in mechanical or aerospace engineering and at least 7 years of aerospace stress analysis experience.

Qualifications

• Bachelor’s degree in Mechanical or Aerospace Engineering.
• Minimum of 7 years of aerospace structural stress analysis experience.
• Experience with static, fatigue, damage tolerance, and FEA.
• Knowledge of FAA requirements, aircraft certification, STCs, or repair substantiation.
• Experience with metallic and composite aircraft structures.
• Familiarity with military standards, parts, and fasteners.
• Proficient in CAD software and structural analysis tools.

Responsibilities

• Perform static, fatigue, and damage tolerance analyses for aircraft structures.
• Develop and validate finite element models using SolidWorks Simulation, Nastran, ANSYS.
• Evaluate structural integrity of metallic and composite components under loading conditions.
• Support aircraft modification programs, including STCs and repairs.
• Generate stress reports and certification documentation in compliance with FAA/EASA.
• Interpret FAA regulations to ensure compliance and testing methods.
• Define and evaluate structural testing to validate models and certification needs.
• Collaborate with design, manufacturing, and certification teams.
• Review drawings and test data to verify performance.
• Provide guidance and technical expertise to team members.
• Manage engineering subcontractors to meet deliverables.
• Design systems meeting customer needs and prepare drawings.

Skills

Static analysis

Fatigue analysis

Damage tolerance

FEA

Finite element modeling

Regulatory compliance

Team leadership

Project management

Stress analysis

Aircraft structures

Education

Bachelor's in Mechanical or Aerospace Engineering

Tools

SolidWorks

Nastran

ANSYS

AutoCAD

CATIA

Job description

Description

We’re Hiring: Aircraft Structural Analysis Engineer II – Stress & FEA

Knight Aerospace is looking for an experienced Aircraft Structural Analysis Engineer II to join our Engineering team in San Antonio, TX.

This is an opportunity to work directly on aircraft modification and certification programs that support military, aerospace, and aeromedical missions. You’ll perform detailed structural analyses, develop and validate finite element models, and help ensure the airworthiness and structural integrity of modified aircraft components and systems.

What You’ll Work On

Static, fatigue, and damage tolerance analysis

Finite element modeling using SolidWorks Simulation, Nastran, ANSYS, or equivalent tools

Metallic and composite aircraft structures

Aircraft modifications, repairs, and STC programs

FAA/EASA stress substantiation and certification documentation

Structural testing and model validation

Collaboration with Design, Manufacturing, Quality, Certification, and Production teams

Technical guidance and management of engineering deliverables

Compensation & Benefits

Base Salary: $80,000-$90,000

Annual Bonus: 5% target

Employer-paid Dental, and Vision coverage

Medical Insurance

401(k) with Company Match

Paid Time Off and Paid Holidays

Long-Term Disability

409A Program

Full-time, 100% on-site in San Antonio, TX

What We’re Looking For

Bachelor’s degree in Mechanical or Aerospace Engineering

At least 7 years of aerospace structural stress analysis experience

Experience with static, fatigue, damage tolerance, and FEA

Knowledge of FAA requirements, aircraft certification, STCs, or repair substantiation

Experience with metallic and composite aircraft structures

Familiarity with military standards, parts, and fasteners

Willingness to support production-floor activities and travel domestically or internationally as needed

The Mechanical Stress Engineer II is responsible for performing detailed structural analyses, supporting certification efforts, and ensuring the airworthiness and structural integrity of modified aircraft components and systems. This will include hands‑on analysis and collaboration across multidisciplinary teams, along with a strong understanding of regulatory compliance and testing requirements. The Mechanical Stress Engineer II will represent the Company and its values and will ensure that expectations are met

Requirements

1. Perform static, fatigue, and damage tolerance analyses for aircraft structures and modifications.
2. Develop and validate finite element models using tools such as SolidWorks Simulation, Nastran and ANSYS.
3. Evaluate structural integrity of metallic and composite components under various loading conditions.
4. Support aircraft modification programs, including STCs (Supplemental Type Certificates) and repairs.
5. Generate stress reports and certification documentation in compliance with FAA/EASA regulations.
6. Interpret and apply FAA regulations to ensure compliance, including identification of acceptable means of compliance and allowable testing methods.
7. Define, support and evaluate structural testing (e.g. static, fatigue, and ground tests) to validate analytical models and certification requirements.
8. Collaborate with design, manufacturing, and certification teams to ensure robust and compliant solutions.
9. Review engineering drawings, models and test data to verify structure performance.
10. Provide guidance and technical expertise to team members, ensuring the successful execution of all projects.
11. Manage engineering subcontractors to meet program deliverables.
12. Design systems and components that meet the needs and requirements of the customer.
13. Produce outlines, concepts, design and final design drawings.
14. Alter and modify designs to meet requirements and to eliminate/reduce manufacturing time.
15. Prepare product drawings and technical documentation in support of customer requirements and deliverables.
16. Drive budget, quality, and schedule deliverables for individual and team tasks

General Expectations:

1. Has a high proficiency operating Auto Cad/Draft Sight, SolidWorks, and SolidWorks PDM or equivalent
2. High proficiency with structural members, 3D mechanical routing, and large assemblies
3. Takes the initiative to find innovative ways of solving complex design issues.
4. Can take on design problems and create designs/drawings with minimal guidance.
5. Will provide training as needed to other engineers/designers
6. Will review designs/drawings/documentation of other engineers/designers
7. Has a working knowledge of UL, FAA, and Military standards
8. Will be team oriented and able to take lead on projects in the group.
9. Reflects the Company’s values in all communications and activities.
10. Ability to effectively communicate orally and in written form, internally and externally.

Qualifications:

1. Bachelor’s degree in Mechanical or Aerospace Engineering
2. Minimum of 7 years of structural stress analysis experience in the Aerospace industry
3. In-depth knowledge of different metals, their properties, and applications for engineering design.
4. Strong familiarity with military standards, parts, and fasteners.
5. Proficiency in CAD software (e.g., SolidWorks, CATIA, AutoCAD) and structural analysis tools.
6. Excellent project management skills, with the ability to handle multiple projects simultaneously.
7. Proven track record in the design, analysis, and implementation of aircraft structural components and systems.
8. Strong problem-solving abilities and attention to detail.
9. Is rigorous and data-driven in decision making.

Work Environment Requirements:

1. Full-Time Position
2. International and domestic travel in support of product designs, implementations, or ongoing service
3. Extensive interaction with production floor activities