Aerospace Interior Stress Analysis Engineer

Job description

KEY RESPONSIBILITIES Stress Analysis & Structural Substantiation •             Perform linear and non-linear FEA using MSC Nastran/Patran, HYPERMESH, ANSYS, or equivalent FEM tools for aircraft interior structural components. •             Conduct static, dynamic (crash/HIC) for seating systems, passenger service units (PSUs), cabin panels, galleys, and monuments. •             Develop and maintain FE models for primary and secondary interior structures including composite and metallic assemblies. •             Execute hand calculations to validate FEA results and provide independent verification of structural margins. •             Perform stress substantiation per applicable FAA/EASA airworthiness regulations (FAR 25, CS-25) and OEM structural design requirements. Product Scope — Interior Structures •             Seating Systems: Economy, business, and first-class seats including track attachment, lug analysis, seat pan, armrest, and recline mechanisms. •             Cabin Panels: Sidewall, ceiling, floor panels — including attachment interface, pressure, and inertia load analysis. •             Galley Structures: Full-size, quarter, and half-galley stress verification including trolley loads, utility connections, and monument interfaces. •             Monuments: Lavatories, crew rest modules, partition walls, dividers — structural adequacy under static and dynamic load conditions. •             Overhead Storage Bins (OSBs): Latching loads, hinge analysis, filling load cases, and door stop analysis. Composite Structures •             Conduct composite laminate analysis — ply-by-ply stress, first-ply failure, progressive failure, and delamination assessment. •             Apply classical lamination theory (CLT) and failure criteria (Tsai-Wu, Tsai-Hill, Maximum Strain). •             Perform bonded joint and fastened joint analysis for composite-to-composite and composite-to-metallic interfaces. •             Collaborate with Materials & Process (M&P) team to define lay-up, fiber orientation, and repair schemes. Certification & Documentation •             Prepare stress reports and substantiation packages in compliance with OEM (Boeing, Airbus, Embraer) and regulatory requirements. •             Support DER/DAR activities for FAA/EASA STC and TC projects. •             Interface with customer engineering, DERs, and certification authorities during design reviews and audits. •             Maintain traceability of load cases, assumptions, and analysis results through structured stress memo system. Collaboration & Design Support •             Work closely with design engineers and program managers throughout the product development cycle (PDR, CDR, TRR). •             Provide design-to-stress feedback for weight reduction and structural optimization initiatives. •             Support test planning, interpret structural test data, and correlate with analytical predictions. •             Mentor junior stress engineers and review analysis deliverables for technical accuracy. QUALIFICATIONS Required Qualifications •             B.E. / B.Tech / M.Tech in Aerospace, Mechanical, or Structural Engineering. •             5–12 years of stress analysis experience in aerospace interiors or aircraft structures. •             Proficiency in MSC Nastran & Patran (pre/post-processing, model building, load application). •             Hands-on experience with ANSYS Mechanical or ANSYS Workbench for FEA. •             Strong knowledge of composite structural analysis and laminate theory. •             Working knowledge of FAR 25 / CS-25 structural airworthiness requirements. •             Experience with interior product types: seats, panels, galleys, or monuments. •             Proficiency in hand-calculation methods: margins, free-body diagrams, joint analysis. Preferred Qualifications •             Experience with Airbus A320/A330/A350 or Boeing 737/777/787 interior programs. •             Familiarity with HIC (Head Injury Criterion) and 16g crash load analysis per FAR 25.562. •             Knowledge of ABD/DMC systems for composite material databases. •             Experience with Hypermesh or FEMAP as pre/post-processing tools. •             Familiarity with CATIA V5/V6 or SolidWorks for geometry interpretation. •             Exposure to STC / TC certification programs with an FAA/EASA DER. •             Knowledge of metallic and non-metallic fastener analysis (Hi-Lok, NAS, Cherry Max). •             Experience with seating TSO-C127b or TSO-C39 certification requirements. TOOLS & SOFTWARE Primary FEA & Analysis Tools MSC Nastran MSC Patran     ANSYS HyperMesh     FEMAP Design & Supporting Tools CATIA V5/V6   SolidWorks      MS Excel / VBA              MATLAB             Python CORE COMPETENCIES Technical •             Structural analysis & margin of safety computation •             FEM model development & validation •             Composite design & failure analysis •             Fatigue & damage tolerance assessment •             Load path interpretation & free-body diagrams Professional •             Strong written & verbal communication •             Ability to work in multi-disciplinary project teams •             Structured problem-solving & analytical thinking •             Attention to detail in technical documentation •             Self-driven with ability to meet tight deadlines