Senior Stress Analyst, Propulsion & 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

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.