Freelance Finite Element Analysis Jobs in Indiana

Prometheus Energetics is seeking an experienced Structural Analyst / Senior Structural Analyst to serve as a primary technical authority for the structural integrity, finite element analysis (FEA), and fracture mechanics of Solid Rocket Motor (SRM) structures. Reporting directly to the Director of Engineering, this role owns the structural lifecycle—from initial sizing and material characterization through coupled load modeling, qualification testing, and high-rate production support.
Solid Rocket Motor hardware operates under severe structural environments: extreme internal pressures, high motor case growth, intense thermal-mechanical stresses, structural vibration, high-g acceleration, and viscoelastic grain strain. The ideal candidate brings 4 to 10 years of hands-on structural engineering experience in composite/metallic pressure vessels, nozzles, or energetic propellant grain mechanics, combining advanced computational modeling skills with practical experience in structural test correlation and factory floor integration.

Key Responsibilities

Structural Design & Material Evaluation

• Lead structural sizing, margin-of-safety assessments, and strength evaluations for solid rocket motor components, including composite filament-wound cases, metallic pressure vessels, nozzle structures, igniter housings, and interstage structures.
• Evaluate orthotropic and anisotropic material behavior for composite structures (e.g., carbon fiber/epoxy wet-wound and prepreg layups) and high-strength metallic alloys (e.g., titanium, maraging steel, aluminum).
• Characterize viscoelastic material behavior, structural margin, and cumulative damage models for solid propellant grains, liners, and insulation bond lines across storage, transportation, thermal cycling, and operational firing profiles.
• Define structural interface requirements, fastener joint designs, skirts, polar cleats, and bond line shear limits to ensure structural integrity across proof testing, flight, and post-burn heat-soak environments.
• Support scalable manufacturing processes (e.g., fiber placement, automated tape laying, hand layup, hydrotesting, and machining) to transition structural designs from prototype into high-rate production.

Structural Modeling & Analysis

• Develop and maintain complex 2D and 3D finite element models (FEM) using industry-standard tools (e.g., Abaqus, ANSYS, Nastran/Patran, HyperMesh, or custom solvers).
• Perform linear and non-linear static, dynamic, modal, random vibration, transient response, and buckling analyses for primary and secondary motor structures.
• Conduct coupled thermal-structural and pressure-stress analyses, incorporating temperature-dependent material properties, internal ballistics pressure-time curves, and aerodynamic flight loads.
• Execute fracture mechanics, damage tolerance, fatigue life, and composite ply-by-ply progressive failure analyses (e.g., Tsai-Wu, Hashin criteria) to establish structural margins of safety.
• Conduct trade studies and optimization to minimize structural mass while maintaining required structural safety factors (e.g., MIL-STD-1522A, NASA-STD-5001).

Structural Testing, Qualification & Model Correlation

• Plan, execute, and analyze structural test campaigns, including hydroburst testing, proof pressure testing, modal survey testing, structural load cell calibration, and environmental vibration/shock tests.
• Collaborate with test engineers to define instrumentation requirements, specifying strain gauge placement, rosette configurations, displacement sensors (LVDTs, DIC), and load cell locations.
• Correlate analytical predictions against measured test data (strain profiles, growth rates, burst pressures, resonance frequencies) to validate and refine finite element models.
• Lead structural root-cause investigations and failure review boards (FRACAS/MRB) for structural anomalies, such as composite delamination, bond line debonding, yield nonconformances, or premature pressure vessel failure.

Cross-Functional Leadership & Program Support

• Work directly with internal ballisticians, thermal analyst counterparts, materials scientists, and manufacturing engineers to deliver fully integrated motor designs on schedule.
• Author clear structural analysis reports (SAR), stress documentation, material design allowables decks, and qualification verification artifacts.
• Present technical findings, margin summaries, and structural design rationale at major program milestones (PDR, CDR, TRR, MRB).
• Serve as a technical mentor to junior engineering staff in finite element techniques, composite failure criteria, and structural verification methodologies.
• Ensure strict compliance with ITAR, EAR, site energetics safety standards, and environmental safety guidelines across all design and lab operations.

Required Qualifications

Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Structural Engineering, or a closely related technical field from an accredited institution.

Experience:

• Structural Analyst: Minimum of 4-6 years of relevant experience in finite element analysis, composite materials stress analysis, or aerospace structural engineering.
• Senior Structural Analyst: 7-10+ years of progressive engineering experience owning structural stress analysis, composite pressure vessel sizing, and structural qualification for solid rocket motors or launch vehicles.
• Proficiency in advanced FEA environments (e.g., Abaqus, ANSYS, Nastran, Patran, HyperMesh) and composite layup analysis tools.
• Strong foundation in solid mechanics, composite materials theory, fracture mechanics, non-linear material response, and fatigue/damage tolerance analysis.
• Direct experience planning or supporting structural testing (hydroburst, proof pressure, strain gauge instrumentation, modal testing).
• Regulatory: U.S. Citizenship required (position involves ITAR/EAR restricted technology).
• Clearance: Ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications

• Master's Degree or Ph.D. in Aerospace, Mechanical, or Structural Engineering with a focus on composite materials, non-linear FEA, or structural dynamics.
• Active U.S. Government Secret Security Clearance.
• Direct experience with Filament Wound Composite Pressure Vessels (COPV), composite skirt joint design, or nozzle structural analysis.
• Experience with viscoelastic material modeling for solid propellant grain structural integrity (slump, thermal stress, storage aging).
• Applied scripting experience in Python, MATLAB, or APDL/Abaqus user subroutines (UMAT/VUMAT) for automated mesh generation, post-processing, or custom material law implementation.
• Knowledge of aerospace pressure vessel standards (e.g., AIAA S-080/S-081, MIL-STD-1522A, NASA-STD-5001).

Work Environment & Physical Requirements

• Work is performed in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas subject to enhanced safety and security controls.