The Senior Structural Analyst leads the finite element analysis (FEA) efforts for complex aerospace structures, ensuring mechanical integrity under static, dynamic, and thermal load conditions. This role drives the development, validation, and documentation of advanced structural models to support design optimization, qualification, and certification of flight hardware. As a technical authority, the senior analyst mentors junior engineers, collaborates across disciplines, and influences system-level mechanical architectures for high-reliability aerospace platforms.
Key Responsibilities:
Lead end-to-end FEA of aerospace structures including static stress, buckling, fatigue, modal, vibration, shock, and random response analyses
Develop sophisticated finite element models using Nastran, Abaqus, ANSYS, or similar tools, incorporating complex material behaviors and nonlinearities
Define load cases based on flight profiles, environments, and customer specifications, and apply advanced boundary conditions and constraints
Perform detailed margin of safety assessments, sensitivity studies, and reliability analyses to ensure structural robustness
Correlate analytical models with test data, identify discrepancies, and drive iterative improvements
Guide and review analysis approaches, results, and documentation prepared by junior and mid-level analysts
Collaborate closely with design, manufacturing, test, systems, and quality engineering teams to ensure structural requirements are met across the product lifecycle
Lead failure investigations, root cause analysis, and structural redesign efforts following anomalies or test failures
Contribute to development and refinement of company-wide FEA standards, methodologies, and automation scripts
Prepare and present technical findings to internal leadership, customers, and certification authorities
Mentor and train engineering staff on best practices in structural analysis and FEA tool usage
Key Focus Areas:
Leadership of complex structural analysis programs for aerospace flight hardware
Advanced modeling techniques including nonlinearities, composites, contact, and multi-physics
Structural validation and certification support
Cross-disciplinary integration and technical mentorship
Continuous improvement of analysis tools and processes
Qualifications & Skills:
Education:
Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or related field (required)
Master’s or PhD in Structural Mechanics, Aerospace Structures, or related discipline preferred
Certifications:
Advanced training or certification in Nastran, Abaqus, ANSYS, or related FEA tools
Professional Engineering (PE) license preferred
Six Sigma, Lean, or DFSS certifications advantageous
Experience:
8–15+ years of structural analysis experience in aerospace, defense, or similar high-reliability industries
Extensive experience with complex FEA modeling for static, dynamic, thermal, and fatigue analyses
Proven ability to lead and manage technical projects and cross-functional teams
Deep knowledge of aerospace materials, joining techniques, and structural design principles
Experience interfacing with customers and certification authorities for structural validation
Technical Skills:
Expert proficiency in FEA software suites (Nastran, Abaqus, ANSYS, HyperMesh, FEMAP)
Strong background in nonlinear analysis, composites modeling, contact mechanics, and fracture mechanics
Ability to script and automate workflows using Python, MATLAB, or other tools
Familiarity with CAD software for geometry extraction and meshing
Thorough understanding of aerospace structural standards and testing protocols (e.g., MIL-STD, NASA-STD, DO-160)
Soft Skills:
Strategic thinker with excellent leadership and mentoring skills
Strong communication skills, capable of presenting complex analyses to technical and non-technical stakeholders
Self-motivated with a proactive approach to problem-solving and continuous improvement
Effective collaborator in multi-disciplinary teams with a focus on quality and schedule adherence