Senior Mechanical Engineer, Stress Analysis
Lever, Inc.
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Benefits offered by this job
Job summary
LTA Research & Exploration is seeking a structures engineer with strong design and analysis fundamentals to tackle aerospace structural challenges in a fast-paced environment in Sunnyvale, CA. You'll perform static, buckling, and modal analyses on airframe and support structures using FEA tools.
Collaborate with cross-functional teams, build and validate FEMs, size components, and document results. The role requires a Bachelor's in ME/Aero, 5+ years, in-person work, CAD, scripting, and joint
Qualifications
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or related field.
- 5+ years of structural design/analysis experience.
- Experience with FEA software (FEMAP/Nastran/ANSYS or similar).
- Strong knowledge of static strength, buckling, and modal/dynamic analysis.
- Proficiency with 3D CAD (SolidWorks/NX or similar).
- Experience with joint analysis (bolted/bonded/welded).
- Scripting experience (Python/MATLAB/VBA) to automate workflows.
- On-site work in Sunnyvale, CA.
Responsibilities
- Perform structural analysis (static, buckling, and modal) on airframe, gondola, and equipment mount structures using FEA tools.
- Develop and maintain finite element models, including mesh generation, load case setup, and post-processing.
- Perform hand calculations to size structures, verify FEA results, and support design trades.
- Size and design structural components from concept to detail CAD.
- Correlate analytical models with test data from static and modal tests.
- Support design trade studies considering weight, strength, manufacturability, and cost.
- Document analysis methodology, assumptions, and results.
- Collaborate with Systems, Avionics, Soft Structures, Materials & Testing, and Manufacturing teams to integrate designs.
- Support fabrication, assembly, and test of prototypes and hardware.
- Investigate and resolve structural issues during build/test/field operations.
- Perform joint analysis to size fasteners, adhesives, and welds.
Skills
Education
Tools
Job description
We're looking for a structures engineer with strong design and analysis fundamentals, someone eager to learn and flexible enough to take on whatever a fast-moving hardware program throws at them. You'll work in an exciting, fast-paced environment tackling some of the most challenging structural problems in aerospace.
- Perform structural analysis (static, buckling, and modal) on airframe, gondola, and equipment mount structures using FEA tools (FEMAP/NX Nastran or equivalent)
- Develop and maintain finite element models, including mesh generation, load case setup, and post-processing of results
- Perform hand calculations to size structures, verify FEA results, and support quick-turn design trades
- Size and design structural components and assemblies, from concept sketches through detailed CAD
- Correlate analytical models against test data (static load tests, modal surveys, ground vibration testing)
- Support design trade studies weighing weight, strength, manufacturability, and cost
- Document analysis methodology, assumptions, and results in formal engineering reports
- Collaborate with Systems, Avionics, Soft Structures, Materials & Testing, and Manufacturing teams to integrate structural designs with the broader vehicle
- Support fabrication, assembly, and test of structural prototypes and hardware
- Investigate and resolve structural issues found during build, test, or field operations
- Perform joint analysis (bolted, bonded, and welded) to size fasteners, adhesives, and welds and substantiate joint margins
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a closely related field
- 5+ years of relevant experience in structural design and/or analysis
- Hands-on experience with FEA software (e.g., FEMAP, Nastran, ANSYS, or similar)
- Highly developed knowledge of structural analysis fundamentals: static strength, buckling, and modal/dynamic analysis
- Proficiency with 3D CAD (SolidWorks, NX, or similar)
- Experience with joint analysis (bolted, bonded, and/or welded joints)
- Scripting/programming experience (e.g., Python, MATLAB, or VBA) to automate analysis and modeling workflows
- Must be able to work on-site in Sunnyvale, California
- Experience with lighter-than-air, aerospace, or other weight-critical vehicle structures
- Experience correlating FEA models to physical test data
- Familiarity with composite structures (CFRP) design and analysis
- Experience with structural dynamics (modal testing, vibration analysis)
- Experience with fatigue analysis and life prediction
- Master's degree in Mechanical or Aerospace Engineering
- Experience in a fast-paced startup or low-volume prototype development environment
- Familiarity with GD&T and manufacturing drawing standards
- Relocation assistance
- Excellent medical, dental, and vision insurance through a PPO plan (100% premium paid for individuals, ~70% for dependents)
- Company-paid life, AD&D, long-term disability, and short-term disability insurances
- Criminal background check clearance
- Drug test clearance wherever applicable
- Applicant must be able to obtain a NASA Moffett Federal Airfield AOA Badge
$150,000 - $190,000 a year
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LTA Research & Exploration welcomes all candidates to apply including those with limited experience. We understand that candidates with a growth mindset and passion for working on the next chapter in aviation advancement can outweigh experience alone. We celebrate diverse origins and journeys and understand their importance in developing new technology. Rooted in our humanitarian mission, we want to serve the entire globe and have a team that represents those we wish to serve.
Lighter Than Air is an equal opportunity employer. All applicants are considered without regard to race, color, religion, national origin, sex, sexual orientation, gender identity or expression, age, disability, marital status, veteran status or any other discriminatory factors prohibited by law.
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