Structural Analysis Engineer

Role Overview

The successful candidate will predominantly work on integrating ZeroAvia's propulsion system onto airframe primary structures including understanding and mitigating against the impact the modifications have on the original aircraft type certificate. The candidate may also be involved in the structural verification of the powertrain and power generation system itself along with rig design.

Key Responsibilities

• Lead structural analysis activities for the design and integration of propulsion and fuel systems into the airframe.
• Perform detailed stress analysis using both numerical (FEA) and classical hand calculation methods to assess strength, stiffness, and durability.
• Conduct and correlate structural simulations with physical test data to validate models and ensure design compliance.
• Participate in design reviews, providing technical input and ensuring structural integrity is maintained throughout the design process.
• Interface with the regulatory authority for demonstration of compliance discussions for the topic of interest
• Collaborate closely with design, manufacturing, and test teams to ensure structural requirements are clearly understood and met.
• Act as a key liaison with the testing department for structural and equipment qualification testing.
• Review and approve subcontractor deliverables related to critical structural components and assemblies.
• Support the development and refinement of structural analysis tools, methods, and best practices.
• Contribute to the full product development lifecycle, from concept through certification and production.
• Provide mentorship and technical guidance to junior engineers within the stress and structures team.

• Bachelor's degree in a relevant engineering discipline (e.g., Aerospace, Mechanical, or Structural Engineering), with a commensurate level of technical experience as a Stress Engineer
• Minimum of 3 years of relevant industrial experience
• Demonstrated depth of experience in the aerospace industry.
• Expert in analytical sizing using hand calculations and industry-standard methods: Bruhn, Niu, ESDU
• High level of expertise in FE model creation, including both GFEM and DFEM, and expertise in one or more types of analysis: linear-static, dynamic, or non-linear.
• Proficient in one or more FEA packages: Simcenter 3D/NX Nastran, MSC Patran/Nastran, HyperMesh/OptiStruct.
• Solid understanding of metallurgy, material models, and failure modes
• Experience of NX including the ability to check CAD models and drawing
• Experience in tool and methodology development.
• Working knowledge of at least one of the following regulations and rules: FAA, EASA, CAA
• Commensurate depth of related Aerospace industry experience
• Fatigue and damage tolerance experience
• Experience in structural testing
• Familiarity with aircraft load generation and computation
• Experience in vibration and shock testing, including knowledge of equipment qualification standards
• Experience in composite material sizing
• Programming experience in Python or MATLAB for developing tools to support structural analysis

Why Join Us?

We want to help you be your best self, at work and at home, that's why we provide our employees with

• Private health and dental care - get access to services and support when you need them. Add your family members too
• Mental health support - enjoy a culture where positive mental health is front of mind with our trained Mental Health First Aiders, Employee Assistance Programmes and wellbeing support.
• Free lunch and healthy snacks - keeping you fueled up so you can help us deliver the technology of the future
• Sports, games and culture clubs - connect and keep fit with other ZeroAvians by joining one of our subsidised clubs - such as, running, cycling, padel, trivia, theatre and gardening.

We also offer:

• Stock options - so you can share in our success.
• 5 hours of free flying lessons
• 25 days holiday, plus public holidays - to help you manage your work-life balance.
• Free EV Charging and membership in our EV Club.
• Salary Sacrifice Schemes for EV Club, Curry's Tech, Cycle to Work, and Ikea Furniture.
• Weekly Spot Bonuses to reward excellence.
• Income Protection and Legal Support for peace of mind.
• Relocation Support to make your move seamless.

As an emergent company shaping the aviation industry, we know that diversity fuels success and unlocks potential. We embrace being an equal-opportunity employer and actively seek individuals from diverse backgrounds. We value the multitude of skills, perspectives, and mindsets everyone can bring to the table. These experiences ignite creativity, originality, and growth. We proudly reject discrimination in all forms, including that based on race, religion, color, national origin, sex, gender expression, sexual orientation, age, marital status, veteran status, or disability status.