Senior Aircraft Stress Engineer - Lead Analysis & Mentoring

Insight Global; Greenville (TX); On-site; USD 120,000 - 160,000; Full time

Job summary

Insight Global is seeking a Senior Aircraft Stress Analysis Engineer in Greenville, TX to lead structural substantiation for aircraft modifications, repairs, and certification efforts. You will apply MSC Nastran/FEMAP to develop FE models and deliver defensible stress results.

You will mentor junior engineers, develop analysis approaches, and collaborate with design teams to ensure airworthiness and compliance with FAA/military standards.

Qualifications

• Bachelor's degree in Mechanical, Aerospace, Aeronautical Engineering or related field.
• 8+ years of aircraft structural or stress analysis experience.
• 8+ years supporting aircraft modifications, repairs, sustainment, or new aircraft development.
• Advanced experience using MSC Nastran and FEMAP.
• Experience creating and maintaining finite element models.
• Strong knowledge of aircraft primary structures and static strength analysis.
• Ability to independently develop structural analysis and substantiation approaches.
• Experience producing and defending structural reports using finite element analysis, hand calculations, and engineering judgment.
• Working knowledge of FAA and military airworthiness requirements.
• Experience reviewing engineering data using CAD and product lifecycle management tools.
• Ability to obtain a U.S. Secret security clearance.

Responsibilities

• Perform classical hand calculations and finite element analysis using MSC Nastran and FEMAP.
• Predict internal loads, stresses, displacements, and margins of safety.
• Analyze fuselage frames, skins, longerons, floor beams, fittings, pressure structures, and structural reinforcements.
• Support aircraft modifications, repairs, sustainment, certification, and airworthiness activities.
• Develop free-body diagrams, load paths, internal load calculations, and structural substantiation.
• Perform static strength analysis and support fatigue and damage tolerance evaluations.
• Create structural test plans, process test data, and establish allowable strength data.
• Prepare and peer review detailed stress and structural substantiation reports.
• Partner with design engineers to develop structurally compliant aircraft modifications and installations.
• Support Material Review Board activities, field modifications, repair substantiation, and engineering investigations.
• Estimate labor requirements and manage forecasts for a small stress engineering team.
• Develop spreadsheets, scripts, and engineering tools that improve analysis efficiency and consistency.
• Manage assigned work within established scope, schedule, and budget.

Skills

MSC Nastran

FEMAP

Finite Element Analysis

Static Strength Analysis

Structural Substantiation

Aerospace Engineering

Team Leadership

Engineering Judgment

Education

Bachelor's degree in Mechanical/Aerospace/Aeronautical Engineering

Tools

CAD/PLM tools

Job description

Insight Global is seeking a Senior Aircraft Stress Analysis Engineer in Greenville, TX to lead structural substantiation for aircraft modifications, repairs, and certification efforts. You will apply MSC Nastran/FEMAP to develop FE models and deliver defensible stress results.

You will mentor junior engineers, develop analysis approaches, and collaborate with design teams to ensure airworthiness and compliance with FAA/military standards.