Structural Repair Engineer II

Leonardo Helicopters; Philadelphia (Philadelphia County); Hybrid; USD 90,000 - 130,000; Full time

Job summary

Leonardo Helicopters is seeking a Repair Engineer to support in-service structural issues for the Americas fleet. You will provide customer-facing engineering support and back-office design/analysis, liaising with global teams to ensure airworthiness and reliability.

The role involves a flexible schedule, weekend work as needed, and potential hybrid work after training. Travel up to 10% and on-call coverage are typical requirements.

Qualifications

• B.S./B.Eng or M.S./M.Eng in Aerospace/Structural/Mechanical Engineering or equivalent with coursework.
• 3–5 years in aerospace structural design/analysis, with 2+ years in sheet metal or composite repairs.
• Strong understanding of aircraft structural design and analysis; FAA/EASA familiarity.

Responsibilities

• Evaluate in-service structural queries and assemble information to determine deliverables.
• Design structural repairs to restore static strength and fatigue tolerance with supervision; draft repair schemes.
• Perform static and fatigue analysis using hand calculations and FEA/FEM under supervision.
• Support incidents requiring extensive structural repair; travel may be required; act as primary point of contact.
• Maintain and improve structural repair manuals with Technical Publications; coordinate updates.

Skills

Aerospace structural design

Static analysis

Fatigue/damage tolerance

CAD experience

Education

B.S./B.Eng or M.S./M.Eng in Aerospace/Structural/Mechanical Engineering or equivalent

Tools

AutoCAD

Catia V4/V5

Job description

Summary of Position

The Repair Engineering group is the focal point for support of in-service structural issues reported by the North, Central, and South American fleet of Customers, Technical Representatives, Repair Stations, and the Fleet Control Center. Individuals within this group are expected to provide both customer-facing engineering support as well as back office engineering design and structural analysis.

Structural Repair Engineers work within a cross-functional, international team of engineers to design and analyze solutions for in-service structural damages. Team members must also liaise with the globally-located engineering functions as part of the company's responsibility to maintain the continued airworthiness of the product lines and to increase the reliability and maintainability of the in-service fleet of aircraft.

This position requires availability to work a flexible schedule including work on weekends and holidays, as necessary, to meet typical and emergent fleet support requirements. One or two extended work days per week, 4-5 weekend days per year, and elected on-call holiday coverage are typical, and vary with workload and business need. A hybrid work schedule may be authorized after an initial training period. Travel typically doesn't exceed 10% of the year and is variable according to business needs.

Please note that this role can be leveled up to SRE III or down to SRE I depending on applicants qualifications.

Essential Duties and Responsibilities

1. Evaluate in-service structural queries/issues (TQ's) for completeness of case information working with query PoC to compile additional information as necessary. Follow appropriate processes and sound engineering judgement to determine appropriate deliverables and provide such deliverables to address structural defects or damages with minimal supervision from senior team members.
2. Design structural repairs following approved/accepted techniques to restore aircraft static strength, fatigue, and damage/flaw tolerance characteristics. Design and develop complex repairs with some supervision from senior team members. Draft structural repair schemes and drawings for repair designs following company rules and best practices to restore aircraft.
3. Perform stress analysis for static strength and fatigue and flaw/damage tolerance of repairs utilizing appropriate hand-calculations, tools/techniques, and FEA/FEM under supervision from senior team members. Write certification reports compiling analysis results as a means of compliance for airworthiness regulations with limited supervision.
4. Provide engineering support for aircraft involved in incidents or otherwise requiring extensive structural repair with minimal supervision from senior team members. Travel to the aircraft/customer location as required with minimal remote supervision. Compile Damage Assessment, Repair Assessment, and other engineering reports as necessary to support such activities under limited supervision. Acts as primary PoC and manage/coordinate such activities to bring project to a successful close.
5. Contribute to the maintenance and improvement of published structural repair manuals through coordination with Technical Publications team to correct errors, clarify repair procedures, and nominate new repairs/procedures for inclusion in the publications. Propose modifications and improvements to procedures or new procedures based upon in-service experience and existing LHD approved data.
6. Support Service Engineering and the Fleet Control Center in resolving AOG issues and providing structural repair solutions during a non-standard work week and weekends with minimal supervision.
7. Various other secondary activities including but not limited to:
   • Providing input and analysis of field data for reliability and maintainability in order to liaise with and drive product improvements through the Design Offices.
   • Creation of structural part variants used for in-service replacement of damaged parts.
   • Providing input and advice to other internal customers as structural specialist.
   • Other related activities from time to time as determined by management.

TOTAL: 100

Qualifications for Position

A. Education

• B.S./B.Eng or M.S./M.Eng. in Aerospace/Structural/Mechanical Engineering or Equivalent Experience + Coursework

B. Experience

• 3-5 Years of aerospace structural design/analysis (at least 2 years experience in design and analysis of sheet metal and/or composite structural repairs required)

C. Competencies & Attributes

• Proficient understanding of aircraft structural design and analysis
• Proficiency in static structural analysis and with some experience in fatigue and damage tolerance analysis (hand calc & FEA)
• Excellent problem solving skills
• Exceptional attention to detail
• Strong verbal and written communication skills
• Working understanding of sheet metal and composite manufacturing techniques
• Working understanding of typical aircraft structural repair procedures
• Proficiency in 2D & 3D CAD (AutoCAD and Catia V4/V5 preferred)
• Working familiarity with applicable FAA/EASA rules and regulations
• Ability to work effectively independently or on a team
• Intercultural awareness, ability to create and maintain relationships
• Customer-focused mindset
• Verbal and written Italian and/or Spanish abilities an advantage

D. Licensure/Certification

• N/A