Senior Stress Engineer

We are seeking an ambitious and capable Senior Stress Engineer to support the integration of novel propulsion systems into existing aircraft designs, contributing to ZeroAvia’s mission to decarbonise aviation. This role will play a key part in delivering effective structural solutions to support aircraft modification and re‑certification activities.

The successful candidate will predominantly focus on the development of ZeroAvia’s power generation system and its integration into primary airframe structures. The role is responsible for the structural verification of the powertrain and power generation systems, including the design and support of associated test rigs.

Responsibilities include the design and analysis of powertrain components and primary airframe structures to accommodate novel propulsion systems. This includes material and hardware selection, proposing solutions to meet stress, stiffness, durability, and damage tolerance requirements, and supporting weight and cost optimisation. Strong experience in both finite element analysis and hand calculations is required, with experience in aircraft design and CS‑23 certified or regional aircraft programmes considered beneficial.

The role requires a strong mechanical engineering background, the ability to work independently, and experience with complex components and assemblies. Experience with aircraft or automotive drivetrain systems is advantageous, as is familiarity with FAA, EASA, and CAA regulatory frameworks.

Requirements

Responsibilities:

• Lead structural analysis activities for design and integration of propulsion and fuel systems. 
• Perform detailed stress analysis using both numerical (FEA) and classical hand calculation methods to assess strength, stiffness, and durability. 
• Conduct and correlate structural simulations with physical test data to validate models and ensure design compliance. 
• Participate in design reviews, providing technical input and ensuring structural integrity is maintained throughout the design process. 
• Interface with the regulation authority for demonstration of compliance discussions for the topic of interest 
• Collaborate closely with design, manufacturing, and test teams to ensure structural requirements are clearly understood and met. 
• Act as a key liaison with the testing department for structural and equipment qualification testing. 
• Review and approve subcontractor deliverables related to critical structural components and assemblies. 
• Support the development and refinement of structural analysis tools, methods, and best practices. 
• Contribute to the full product development lifecycle, from concept through certification and production. 
• Provide mentorship and technical guidance to junior engineers within the stress and structures team. 

Experience Required:

• Bachelor’s degree in a relevant engineering discipline (e.g. Aerospace, Mechanical, or Structural Engineering), with a commensurate level of technical experience as a Stress Engineer
• Minimum of 3 years’ relevant industrial experience in a stress or structural analysis role
• Demonstrated depth of experience within the aerospace industry
• Strong experience in analytical sizing using hand calculations and industry‑standard methods (e.g. Bruhn, Niu, ESDU)
• High level of expertise in finite element model creation, including both GFEM and DFEM
• Experience performing one or more types of analysis, including linear static, dynamic, and/or non‑linear analysis
• Proficiency in one or more FEA packages such as Simcenter 3D / NX Nastran, MSC Patran/Nastran, or HyperMesh/OptiStruct
• Solid understanding of metallurgy, material models, and structural failure modes
• Experience using NX, including the ability to review and check CAD models and drawings
• Experience in tool and methodology development to support structural analysis activities
• Working knowledge of at least one relevant regulatory framework (e.g. FAA, EASA, or CAA)
• Experience in fatigue and damage tolerance analysis
• Experience supporting or conducting structural testing, including correlation activities
• Familiarity with aircraft load generation and load computation
• Experience in vibration and shock testing, including knowledge of equipment qualification standards
• Experience in composite material sizing and analysis
• Programming experience in Python and/or MATLAB for developing analysis and productivity tools

Skills & Competencies

• Excellent interpersonal skills with strong written and verbal communication ability
• Excellent level of spoken and written English (additional languages are a plus)
• Ability to work independently using own initiative, as well as collaboratively within a small, multidisciplinary team
• Comfortable working from first principles and applying sound engineering judgement

Benefits

At ZeroAvia, we’re clean sky thinkers. For the world to achieve truly clean, guilt-free flight, we need a scalable solution; hydrogen-electric powertrains. As a leader in zero-emission aviation and a UK Jet Zero Council member, we’re designing and commercialising hydrogen-powered solutions that will positively impact the future of aviation, global connectivity, and the world. 

Join us at our Global HQ in Cotswold Airport, home to some of our aircraft and the workplace of many ZeroAvians. Located just outside the historic market town of Cirencester, you’ll experience a workspace built by engineers for engineers. This is a high-velocity and fast-paced environment with good links to the M4 and M5, so it’s fitting that it’s also our UK Head Office.

Why Join Us? 

We want to help you be your best self, at work and at home, that’s why we provide our employees with… 

• Private health and dental care – get access to services and support when you need them. Add your family members too.
• Mental health support – enjoy a culture where positive mental health is front of mind with our trained Mental Health First Aiders, Employee Assistance Programmes and wellbeing support. 
• Free lunch and healthy snacks – keeping you fuelled up so you can help us deliver the technology of the future** 
• Sports, games and culture clubs – connect and keep fit with other ZeroAvians by joining one of our clubs – such as, running, cycling, padel, trivia, theatre and gardening. 

We also offer:  

• Stock options – so you can share in our success. 
• 25 days holiday, plus public holidays and additional days awarded for long service – to help you manage your work-life balance.
• Free EV Charging and membership in our EV Club. 
• Salary Sacrifice Schemes for EV Club, Curry's Tech and Cycle to Work
• Weekly Spot Bonuses to reward excellence. 
• Income Protection and Legal Support for peace of mind. 
• Relocation Support to make your move seamless.

Diversity and Inclusion

As an emergent company shaping the aviation industry, we know that diversity fuels success and unlocks potential. We embrace being an equal-opportunity employer and actively seek individuals from diverse backgrounds. We value the multitude of skills, perspectives, and mindsets everyone can bring to the table. These experiences ignite creativity, originality, and growth. We proudly reject discrimination in all forms, including that based on race, religion, color, national origin, sex, gender expression, sexual orientation, age, marital status, veteran status, or disability status.