Stress Engineer

This role focuses on advanced structural analysis and finite element modeling of aircraft structures, with a strong emphasis on composite airframe components. The Stress Engineer builds, validates, and correlates detailed FEM, GFEM, and DFEM models, supports structural testing and inspections, and helps define and standardize analysis methods and criteria. The position requires deep experience in aircraft stress engineering, particularly in composites and FEA tools such as FEMAP and HyperSizer/HyperX, to ensure structural integrity and compliance with design and loads requirements.

Responsibilities

• Review, update, and compile the analytical definition of structural components and assemblies based on records from prototype build projects.
• Develop standardized analysis criteria, methods, and templates for structural analysis of aircraft components and assemblies.
• Build, refine, and manage finite element models (FEM, GFEM, DFEM), including break-out models and full aircraft models, to support structural analysis and sizing.
• Validate and correlate structural models using test data, including FEM/strain gage data correlation, to ensure accuracy and reliability.
• Play an integral role in the workflow release process for all structural designs, ensuring that analysis supports design decisions and release milestones.
• Support the review of manufacturing plans and procedures to ensure compliance with design intent, loads requirements, and structural integrity standards.
• Support the creation of structural test plans to verify manufacturing quality and confirm structural performance against requirements.
• Oversee and coordinate the work of other Stress Engineers and act as a Commodity Stress focal point for assigned structures.
• Handle pre- and post-flight structural non-routine issues (NRIs) for fuselage structures and review the NRI work completed by other team members.
• Manage inspection inquiries, requests, and new inspection definitions from internal inspection and quality teams.
• Define primary structure inspections as needed to support flight test campaigns and entry into service (EIS).
• Compile, refine, and implement tools, methods, and procedures learned from projects, and share best practices with the broader team.
• Collaborate closely with design, manufacturing, test, and operations teams to resolve structural issues and optimize designs.
• Document analysis results, assumptions, and methodologies clearly and thoroughly, and present findings in written reports and technical presentations.
• Use classical stress analysis techniques, including free-body diagrams and strength of materials methods, to supplement finite element analysis.
• Support continuous improvement of analysis workflows, automation, and templates to increase efficiency and consistency across programs.

• Bachelor’s degree from an accredited institution in a relevant engineering discipline.
• Minimum 10 years of applicable experience in the analysis of structural systems using strength of materials and finite element–based methods.
• Minimum 10 years of total stress engineering experience, with extensive aircraft and airframe exposure.
• Minimum 5 years of experience with strong understanding of composites analysis, including manufacturing and sizing of composite structures.
• Minimum 5 years of experience with strong understanding of FEA models, including pre- and post-processing of NASTRAN models and associated sizing of composite structures.
• Minimum 3 years of experience supporting structural tests with practical knowledge of FEM/strain gage data correlation.
• 8–10 years dedicated to finite element modeling of aircraft structures, including FEM, GFEM, and DFEM.
• Demonstrated airframe experience, particularly with composite aircraft structures.
• Strong proficiency with FEMAP for finite element modeling and analysis.
• Experience with HyperSizer or HyperX for structural sizing and optimization.
• Ability to build, manage, and validate full aircraft models as well as detailed break-out models.
• Experience in model correlation and validation using test data and established methods.
• Proficiency in stress analysis and finite element analysis for aircraft structures.
• Experience with CATIA V5 for interaction with design geometry and models.
• Experience with NASTRAN for structural analysis of metallic and composite structures.
• Strong understanding of structural analysis of composite and metallic structures, including sizing and margins of safety.
• Experience with free-body diagrams and classical stress analysis techniques.
• Excellent verbal and written communication skills for collaboration and documentation.
• Excellent organizational and problem-solving skills to handle complex structural issues.
• Proficiency with standard office software, including Outlook, Word, Excel, and PowerPoint.

• Hands-on experience with composite part fabrication and assembly processes.
• Proficiency in FEMAP beyond basic usage is considered a strong plus.
• Pilot experience, aircraft homebuilding, or rapid prototyping experience is highly valued.
• Experience with the design of flight vehicles or vehicle systems to requirements or standards such as CFR 14 Part 400, Part 23, Part 25, or comparable military or NASA standards.
• Experience with manufacturing-based ERP systems, such as Oracle, is a plus.
• Experience handling stress analysis for airframe composite structures over at least 5 years.
• Ability to compile and implement new tools, methods, and procedures and share them effectively with the team.
• Strong teamwork skills and the ability to coordinate with multiple disciplines in a fast-paced engineering environment.

This role supports multiple openings across all experience levels within a dynamic aerospace engineering environment focused on aircraft structural design and analysis. The work relies heavily on advanced engineering software tools, including FEMAP, NASTRAN, HyperSizer/HyperX, CATIA V5, and standard office applications such as Outlook, Word, Excel, and PowerPoint. The position operates on a standard five-day work week with no alternative work schedule and requires working in alignment with Pacific Time hours. Collaboration with design, manufacturing, test, and inspection teams is frequent, and the environment emphasizes rigorous analysis, thorough documentation, and cross-functional communication. Team members receive paid holidays, accrue two weeks of paid time off, and accrue three days of sick leave in accordance with local requirements.

Job Type & Location

This is a Contract position based out of Mojave, CA.

The pay range for this position is $60.00 - $90.00/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following:
• Medical, dental & vision
• Critical Illness, Accident, and Hospital
• 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)

This is a fully remote position.

This position is anticipated to close on May 18, 2026.

Diversity, Equity & Inclusion

At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I is embedded into our culture through:

• Hiring diverse talent
• Maintaining an inclusive environment through persistent self-reflection
• Building a culture of care, engagement, and recognition with clear outcomes
• Ensuring growth opportunities for our people

Actalent is an equal opportunity employer.

About Actalent

Actalent is a global leader in engineering and sciences services. For more than 40 years, we’ve helped visionary companies advance their goals. Headquartered in the United States, our teams span 150 offices across North America, EMEA, and APAC—with four delivery centers in India led by 1,000+ extraordinary employees who connect their passion with purpose every day.

Our Bangalore, Hyderabad, Pune, and Chennai delivery centers are hubs of engineering expertise, with core capabilities in mechanical and electrical engineering, systems and software, and manufacturing engineering. Our teams deliver work across multiple industries including transportation, consumer and industrial products, and life sciences. We serve more than 4,500 clients, including many Fortune 500 brands. Learn more about how we can work together at actalentservices.com.