Senior Aircraft Stress Analysis Engineer

Insight Global; Greenville (TX); On-site; USD 120,000 - 170,000; Full time

Job summary

Insight Global is seeking two Senior Stress Analysis Engineers in Greenville, TX to lead complex aircraft modification, certification, and sustainment programs. You will independently develop and apply structural analysis methods, mentor technical teams, and collaborate with design engineers to meet FAA and military airworthiness requirements.

Ideal candidates bring extensive experience with MSC Nastran/FEMAP, fatigue and damage tolerance, and tool development using VBA, Python, or MATLAB.

Qualifications

• Bachelor’s degree in Mechanical, Aerospace or Aeronautical Engineering.
• 8+ years of aircraft structural/stress analysis experience.
• 8+ years in supporting aircraft modifications, repairs, sustainment or new development.
• Ability to obtain a Secret Clearance.
• Advanced proficiency using MSC Nastran and FEMAP for aircraft structural analysis.
• Experience analyzing primary structures and structural reinforcements.
• Experience developing engineering tools using VBA, Excel macros, Python, MATLAB, or similar.
• Previous technical lead or mentorship experience within a structural analysis group.
• Experience with military aircraft, ISR platforms, or business jet modifications.

Responsibilities

• Perform hand calculations and develop finite element models to predict loads, displacements, stresses, and margins of safety.
• Analyze fuselage frames, skins, longerons, floor beams, fittings and reinforcements.
• Support modifications, repairs, and sustainment on FAA Part 25 aircraft.
• Create stress reports and substantiation for certification and airworthiness.
• Conduct static strength, fatigue, and damage tolerance analysis as required.
• Develop test plans, process test data, and establish allowable strength data.
• Peer review stress reports and collaborate with design engineers for FAA/military compliance.
• Review CAD/PLM data to ensure structural requirements are incorporated.
• Support MRB activities, repair substantiation, and investigations as needed.
• Estimate labor hours and manage a small team of stress engineers.
• Develop analysis automation tools and engineering utilities.

Skills

Leadership/mentoring

Secret Clearance

Static strength analysis

Aerospace structural analysis

Education

Bachelor’s degree in Mechanical/Aerospace/Aeronautical Engineering

Tools

MSC Nastran

FEMAP

CAD/PLM tools

VBA/Excel/Python/MATLAB

Job description

Job Description

An employer in Greenville, TX is seeking two experienced Senior Stress Analysis Engineers to support complex aircraft modification, certification, sustainment, and repair programs. This role is ideal for engineers who bring strong structural fundamentals, adaptable analysis skills, and a leadership mindset, and who are comfortable working outside of rigid OEM-specific toolchains. Engineers who enjoy mentoring and leading technical teams, rather than solely performing individual contributor analysis work, will be a great fit for this opportunity. We are specifically interested in engineers who can independently develop and apply structural analysis methods, tools, and substantiation approaches rather than relying solely on proprietary OEM processes.

Responsibilities

• Perform classical hand calculations and develop finite element models (MSC Nastran/FEMAP) to predict internal loads, displacements, stresses, and margins of safety for aircraft structures.
• Analyze aircraft primary structure including fuselage frames, longerons, skins, floor beams, fittings, pressure structure, and major structural reinforcements.
• Support major aircraft modifications, repairs, and sustainment activities on FAA-certified (14 CFR Part 25) fixed-wing transport and business jet aircraft.
• Generate free-body diagrams, internal load paths, margins of safety, and structural substantiation using accepted aerospace engineering methodologies.
• Perform static strength analysis and support fatigue and damage tolerance evaluations as required.
• Develop structural test plans, post-process test data, and establish allowable strength data to support certification and airworthiness findings.
• Generate and peer review detailed stress reports supporting aircraft certification, repairs, modifications, and airworthiness compliance.
• Collaborate closely with design engineers to develop aircraft modifications and installations that satisfy FAA and military airworthiness requirements.
• Review engineering design data using CAD and PLM tools to ensure structural requirements are properly incorporated into the design.
• Support Material Review Board (MRB), repair substantiation, field modifications, and engineering investigations as needed.
• Manage assigned tasks within scope, budget, and schedule requirements.
• Estimate engineering labor hours for proposals and manage labor forecasts for a small team of stress engineers.
• Develop analysis automation tools, spreadsheets, scripts, or engineering utilities to improve efficiency and standardize analysis methods.

Skills and Requirements

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Aeronautical Engineering, or a related engineering discipline.
• 8+ years of aircraft structural/stress analysis experience.
• 8+ years of experience supporting aircraft modifications, repairs, sustainment activities, or new aircraft development.
• Ability to obtain a Secret Clearance
• Advanced proficiency using MSC Nastran and FEMAP for aircraft structural analysis.
• Experience analyzing aircraft primary structures including fuselage frames, skins, longerons, floor beams, fittings, and structural reinforcements.
• Strong understanding of static strength analysis methods and the ability to independently develop structural analysis approaches.
• Experience generating and defending aircraft structural substantiation reports using a combination of finite element analysis, classical hand calculations, and sound engineering judgment.
• Experience developing free-body diagrams, internal load calculations, margins of safety, and structural compliance documentation.
• Working knowledge of FAA and military airworthiness requirements related to aircraft structures and static strength substantiation.
• Experience reviewing engineering design data utilizing CAD and PLM tools.
• Experience performing fatigue and damage tolerance analysis utilizing NASGRO or similar tools.
• Experience supporting MRB activities, repair substantiation, or aircraft sustainment programs.
• Experience developing engineering tools utilizing VBA, Excel macros, Python, MATLAB, or similar software.
• Prior experience serving as a technical lead, team lead, or mentor within a structural analysis organization.
• Experience with military aircraft, ISR platforms, special mission aircraft, or business jet modifications.

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal employment opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment without regard to race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or the recruiting process, please send a request to [e-mail].