Senior Stress Engineer

Job Title: Lead Stress Analysis Engineer

Location: Tallassee, AL

Tata Technologies is seeking a Lead Stress Analysis Engineer to lead and manage the static analysis of fuselage and wing structures for utility aircraft. The role requires deep expertise in metallic and composite stress analysis, DFEM/GFEM modelling, certification compliance, and weight optimization. The Lead Stress Engineer will be responsible for planning, reviewing, and approving analysis deliverables, ensuring analytical rigor, and supporting certification activities while mentoring junior stress engineers and driving collaboration across design, loads, and manufacturing functions.

Dimension of Function

Accountable for leading structural analysis activities across the design lifecycle — from concept through certification. Oversees development and validation of FEM models, structural sizing, and stress reports. Applies advanced knowledge of stress methods, material behaviour, and certification standards to ensure robust and certifiable structures. Provides technical leadership to stress teams and ensures alignment with program requirements and regulatory guidelines.

Contacts

Works closely with design, loads, and manufacturing teams to validate and optimize structures. Interfaces with project leads, certification authorities, and customer representatives to ensure compliance, alignment, and timely delivery of stress analysis deliverables.

Area of Responsibility

• Lead static stress analysis for fuselage and wing structures under multiple load conditions.
• Define analysis strategy, allocate tasks, and review work of stress engineering teams.
• Develop and validate DFEM/GFEM models to support structural integrity assessments.
• Approve stress reports, justification dossiers, and certification documentation.
• Provide technical leadership in material allowable, stress methods, and weight optimization.
• Review and validate hand calculations to cross-check FEM results.
• Support design reviews, trade-off studies, and structural improvement initiatives.
• Collaborate with Loads, Design, and Manufacturing teams to ensure design feasibility and producibility.
• Interface with certification authorities to align with FAR 23 / FAR 25 / FAR 27 requirements.
• Provide stress support during prototype build, ground tests, and flight test campaigns.
• Mentor and develop junior stress engineers, ensuring skill growth and knowledge transfer.

Key Must Have’s:

• 10–15 years of experience in aerospace structural stress analysis.
• Bachelor’s degree in Aerospace / Mechanical Engineering (Master’s degree preferred).
• Proven expertise in FEM tools (NASTRAN, PATRAN, HyperMesh, or equivalent).
• Well versed with composite design principles & evaluating using FEM & FEA
• Strong knowledge of DFEM/GFEM meshing and validation methodologies.
• In-depth understanding of both metallic and composite structural behavior.
• Hands-on experience in classical hand calculations and analytical stress methods.
• Familiarity with aerospace certification requirements (FAR 23, FAR 25, FAR 27).
• Experience on commercial aircraft, business jets, or eVTOL/UAV platforms preferred.
• Strong project management, leadership, and technical review skills.
• Excellent technical writing and presentation skills for customer and authority engagement