Lead Stress Analyst - Propulsion and Fluids at Firefly Aerospace in TX

Job description

• As the Lead Stress Analyst for Propulsion & Fluid Systems in the Mechanical Engineering department, you will provide technical leadership for the structural analysis of propulsion and fluid system hardware. You will own the structural integrity of engine and fluid-system components from early design through qualification and flight across multiple product lines.
• This is a technical leadership role. You will define analysis methods, drive the most complex and highest-risk analyses, set the technical direction for propulsion & fluid systems stress, and be a key voice in decisions on material allowables. You will provide technical guidance and mentorship to other analysts and review internal and external analyses. You will work closely with design, materials, manufacturing, and test engineers to deliver structurally robust, weight-efficient hardware that meets program and customer requirements. To be successful, you should be able to independently scope, execute, review, and defend structural analyses.

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 (fatigue, fracture, and damage tolerance) analyses to guide design decisions and ensure strength, stability, stiffness, and life requirements are met
• 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

Requirements

• Required
• B.S. in Aerospace, Mechanical, or a related engineering discipline
• 5+ years of relevant experience in structural/stress analysis and qualification of aerospace or comparable high-performance hardware
• Proficiency with finite element analysis (Ansys and/or Nastran) and classical hand analysis, with strong model validation and verification skills
• 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
• Strong understanding of structural mechanics, load paths, and first principles related to structures and materials
• M.S. or PhD in Aerospace, Mechanical, or a related engineering field
• Experience with analysis of liquid propulsion components, fluid systems, or rocket engine hardware
• Experience with analysis of turbomachinery hardware
• Experience with crack-growth / fracture software such as NASGRO or AFGROW
• Experience with additive manufacturing structural analysis and material characterization
• Experience correlating structural predictions with test or flight data

Skills

Required

• Classical hand analysis