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Senior Damage Tolerance Engineer Jobs (NOW HIRING)

AEVEX

Sr. Stress Engineer

Murrieta, CA · On-site

$200K - $224K/yr

The Senior Stress Engineer at AEVEX Aerospace is responsible for analyzing primary & secondary ... Develops Fatigue & Damage Tolerance (F&DT) reports * Other functions may include basic thermal ...

Eclipse Aerospace

Stress Engineer

Albuquerque, NM · On-site

$95K - $130K/yr

Stress Engineer If you are interested joining an organization with a reputation for outstanding ... Perform static strength, fatigue analysis, and damage tolerance analysis based on various loading ...

Expleo

Stress Engineer VI - Tulsa

Tulsa, OK · On-site

$90/hr

Perform and oversee advanced static, fatigue, and damage tolerance analysis * Define and drive ... Mentor senior engineers and shape organizational technical capability * Drive innovation and ...

Spirit AeroSystems

Structural Analysis Engineer

Wichita, KS · On-site

$118K - $182K/yr

... damage tolerance analysis, thermal analysis, vibration analysis, structural testing, etc.) to ... Range Senior Engineer (Level 4): $118,750 - $182,100 Kansas Tax Credit: Join Spirit AeroSystems ...

Expleo

Stress Engineer VI - Tulsa

Tulsa, OK · On-site

$90/hr

Perform and oversee advanced static, fatigue, and damage tolerance analysis * Define and drive ... Mentor senior engineers and shape organizational technical capability * Drive innovation and ...

Spirit AeroSystems

Structural Analysis Engineer

Wichita, KS · On-site

$118K - $182K/yr

... damage tolerance analysis, thermal analysis, vibration analysis, structural testing, etc.) to ... Range Senior Engineer (Level 4): $118,750 - $182,100 Kansas Tax Credit: Join Spirit AeroSystems ...

Quantum World Technologies Inc

Stress Engineer

Wichita, KS · On-site

$52.50 - $72/hr

Stress Engineer Location: Wichita, KS Onsite/ Remote: Onsite In this role, you will be a critical ... Perform detailed fatigue and damage tolerance (F&DT) analyses on primary and secondary aircraft ...

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Senior Damage Tolerance Engineer information

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$59.5K

$126.6K

$183.5K

How much do senior damage tolerance engineer jobs pay per year?

As of Jun 9, 2026, the average yearly pay for senior damage tolerance engineer in the United States is $126,557.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,500.00 and $143,500.00 per year, depending on experience, location, and employer.

What are Senior Damage Tolerance Engineers?

Senior Damage Tolerance Engineers are specialized professionals who assess and predict the structural integrity and lifespan of materials and components, particularly in aerospace and automotive industries. They analyze how cracks, flaws, and other damage can affect the strength and safety of structures over time. Using advanced analytical methods and simulation tools, they help ensure that products meet safety standards and regulatory requirements. Their expertise is critical for maintaining the safety and reliability of aircraft, spacecraft, and other complex systems.

What are the key skills and qualifications needed to thrive as a Senior Damage Tolerance Engineer, and why are they important?

To thrive as a Senior Damage Tolerance Engineer, you need a deep understanding of fracture mechanics, fatigue analysis, and materials science, usually supported by an engineering degree and significant aerospace industry experience. Expertise with finite element analysis (FEA) software, damage tolerance assessment tools, and familiarity with industry standards and certification processes is essential. Strong problem-solving, attention to detail, and effective communication skills help you interpret complex data and collaborate with cross-functional teams. These skills and qualities are crucial for ensuring aircraft structural integrity and safety while meeting regulatory and operational requirements.

What is the difference between Senior Damage Tolerance Engineer vs Damage Tolerance Engineer?

AspectSenior Damage Tolerance EngineerDamage Tolerance Engineer
QualificationsTypically requires 5+ years experience, advanced certificationsEntry to mid-level, relevant engineering degrees
ResponsibilitiesLeading damage assessments, overseeing projects, mentoringPerforming damage analysis, supporting design and testing
Work EnvironmentDesign offices, testing labs, aerospace or defense industriesDesign offices, testing labs, aerospace or defense industries

The main difference is experience level and responsibility. Senior Damage Tolerance Engineers lead damage assessments and mentor teams, while Damage Tolerance Engineers focus on analysis and supporting project tasks. Both roles are vital in aerospace and defense sectors, requiring similar credentials and work environments.

What are some common challenges faced by Senior Damage Tolerance Engineers when evaluating aircraft structural integrity?

Senior Damage Tolerance Engineers often encounter challenges when analyzing complex stress and fatigue data, especially for aging aircraft or when new materials are involved. Balancing safety margins with weight and cost constraints requires careful judgment and up-to-date knowledge of regulatory standards. Collaboration with design, materials, and maintenance teams is crucial to ensure that repairs and modifications meet both safety and operational requirements. Staying current with evolving industry guidelines and advanced simulation tools is also essential for success in this role.
What cities are hiring for Senior Damage Tolerance Engineer jobs? Cities with the most Senior Damage Tolerance Engineer job openings:
What are the most commonly searched types of Damage Tolerance Engineer jobs? The most popular types of Damage Tolerance Engineer jobs are:
What states have the most Senior Damage Tolerance Engineer jobs? States with the most job openings for Senior Damage Tolerance Engineer jobs include:
Senior Damage Tolerance Engineer jobs near you
Infographic showing various Senior Damage Tolerance Engineer job openings in the United States as of May 2026, with employment types broken down into 96% Full Time, 1% Part Time, 1% Temporary, and 2% Contract. Highlights an 96% Physical, 2% Hybrid, and 2% Remote job distribution, with an average salary of $126,557 per year, or $60.8 per hour.

Sr. Stress Engineer

AEVEX

Murrieta, CA • On-site

$200K - $224K/yr

Full-time

Medical, Dental, Vision, Life, Retirement

Posted 7 days ago

Job description

The Senior Stress Engineer at AEVEX Aerospace is responsible for analyzing primary & secondary aircraft structures to show compliance with FAA 14CFR Part 23 & Part 25 regulations. These analyses include loads development, classical hand calculations, Finite Element (FEM) modeling, fatigue & damage tolerance assessment and testing of aircraft modifications involving both metallic & composite structure and are thoroughly documented in formal structural substantiation reports.
Essential Functions:
  • Provides stress analysis of metallic & composite structures using classical hand calculations and finite element modeling (FEM) with advanced meshing techniques
  • Performs loads develop in support of static, dynamic and fatigue & damage tolerance assessments
  • Develops Fatigue & Damage Tolerance (F&DT) reports
  • Other functions may include basic thermal analysis, basic aero-elastic flutter, dynamic response, non- linear analysis, pre- and post-test analysis, structural optimization, and software programming
  • Completes stress notes & develops macros using Excel and Mathcad or similar software
  • Documents analyses in formal structural substantiation reports and other airworthiness documents
  • Contributes to FAA STC Project Specific Certification Plans (PSCP)
  • Interfaces with Design Engineers to determine structural load paths and design optimization
  • Reviews & approves engineering drawings & reports • Attends design reviews as necessary
  • Regular and reliable attendance on a full time basis [or in accordance with posted schedule].
  • Responsible for exhibiting professional behavior with both internal and external business associates that reflects positively on the company and is consistent with the company's policies and practices.
  • Embodies AEVEX's cultural values and aligns daily actions with department goals and company culture.

Qualifications and Competencies:
  • Ability to obtain and maintain a Secret Security Clearance (US Citizenship required)
  • Familiarity with resources such as MMPDS, Bruhn, Roark, etc., aircraft fasteners, materials, sheet metal assemblies, machined fittings, composites (fiberglass/carbon fiber), and honeycomb and solid laminate construction
  • Knowledge of and familiarity with 14 CFR Part 23 and Part 25 structures regulations
  • Strong foundation in technical skills, such as stress analysis, FEM, and solid modeling.
  • Solid understanding of engineering modeling techniques and principles
  • Experience reviewing and interpreting engineering models, drawings and manuals
  • Strong organizational, analytical and problem solving skills
  • Ability to evaluate, document, and report information regarding designs based on structural trade studies
  • Experience with sheet metal modeling techniques for aircraft structures
  • Strong communication skills, both written and verbal.
  • Proficient in MS Office for report writing and analysis preparation
  • Ability to work collaboratively with the engineering team and cross functionally
  • Proficient in writing technical reports and presenting data in a clear and concise manner
  • Driven self starter with a strong sense of accountability

Education / Certifications:
  • Degree in Aerospace or Mechanical Engineering or equivalent experience required

Experience:
  • 8-10 years of classical aircraft hand stress analysis methods and NASTRAN (FEMAP) finite element modeling
  • Experience with primary & secondary structural modifications on aircraft

Physical Requirements: The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties the employee is: Constantly required to sit, and to reach to use computers and other office equipment. For this summary, occasionally is used to represent up to 1/3 of the time given to the work day, frequently represents 1/3 to 2/3 of the time and constantly represents 2/3 or more of the time.
AEVEX provides a reasonable range of compensation. Actual compensation is influenced by an array of factors including, but not limited to, skill set, level of experience, and specific location. The range of starting pay for this position is for the listed location only.
Salary Range
$200,000-$224,000 USD
About AEVEX
AEVEX, headquartered in Solana Beach, California, supports the U.S. national security mission and partner nation needs around the world by providing full-spectrum aviation, remote sensing, and analysis solutions. The company's capabilities include custom design and engineering; rapid prototyping; sensor integration and sustainment; aircraft modification and certification; flight test instrumentation and support; mission operations service; advanced intelligence data processing, exploitation, and dissemination solutions; and tailored hardware and software mission-system tools. AEVEX uses agile and customized approaches to rapidly define, develop, and deliver specialized solutions for airborne special mission needs for the U.S. Government, partner nations, and commercial businesses. AEVEX has major offices in California, Florida, North Carolina, Ohio, and Virginia.
AEVEX provides a full suite of comprehensive benefits, including a 401(k)-retirement plan, comprehensive Medical, Dental, Vision, Disability and Life insurance group coverage with a portion of the premiums paid by the company, professional development funds, and an Employee Assistance Plan (EAP) with counseling, legal help, child and elder care support, among other benefits for qualified employees.
Equal Employment Opportunity:
AEVEX is an Equal Opportunity employer. We are committed to providing equal employment opportunities to all employees and applicants without regard to race, religious creed, color, sex (including pregnancy, breast feeding and related medical conditions), gender, gender identity, gender expression, sexual orientation, national origin, ancestry, citizenship status, military and veteran status, marital status, age, protected medical condition, genetic information, physical disability, mental disability, or any other protected status in accordance with all applicable federal, state and local laws.

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