Aerospace Interior Stress Analysis Engineer

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