Senior Structural Test Engineer – Aerospace & Composites

Archer; San Jose (CA); On-site; USD 188,000 - 197,000; Full time

Job summary

Archer in San Jose, CA seeks a Senior Structural Test Engineer to lead structural testing, FEM analysis, and substantiation for an all-electric aircraft program. You will guide design concepts and mentor junior analysts while ensuring compliance with FAA airworthiness requirements.

The role requires a bachelor’s in aerospace or mechanical engineering and 6+ years in composite and metallic analysis, with CATIA V5 and Abaqus experience. Domestic travel is expected.

Qualifications

• Bachelor’s degree in Aerospace or Mechanical Engineering; required.
• 6 years of experience in Composite and Metallic analysis (static and fatigue), design engineering, and instrumentation engineering.
• Master’s Degree in Aerospace or Mechanical Engineering; preferred.
• PhD Degree in Aerospace or Mechanical Engineering; alternative qualification path.
• Alternate experience: 2 years with CATIA V5 and Abaqus for composites; model setup and analysis.

Responsibilities

• Perform airframe structural testing, including fixtures and instrumentation design.
• Carry out trade studies and establish vehicle configuration from requirements.
• Execute hand calculations and FEM analysis of primary and secondary structures.
• Develop company standards for model creation, strength checks, and analysis reports.
• Compile stress analysis documentation to support engineering drawings release.
• Mentor designers and junior analysts in stress, stability, and fracture analysis best practices.
• Provide technical guidance on design concepts balancing risk, cost, and performance.
• Perform stress analysis (FEM) for internal loads, static, fatigue, and damage tolerance.
• Support test execution and analyze results to verify designs meet requirements.
• Write structural substantiation and other reports to obtain FAA airworthiness approvals.

Skills

Structural analysis

Airframe testing

FEM analysis

Education

Bachelor’s degree in Aerospace or Mechanical Engineering

Master’s Degree in Aerospace or Mechanical Engineering

PhD Degree in Aerospace or Mechanical Engineering

Tools

CATIA V5

Abaqus

Job description

Archer in San Jose, CA seeks a Senior Structural Test Engineer to lead structural testing, FEM analysis, and substantiation for an all-electric aircraft program. You will guide design concepts and mentor junior analysts while ensuring compliance with FAA airworthiness requirements.

The role requires a bachelor’s in aerospace or mechanical engineering and 6+ years in composite and metallic analysis, with CATIA V5 and Abaqus experience. Domestic travel is expected.