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Senior Stress Engineer Jobs (NOW HIRING)

AEVEX

Sr. Stress Engineer

Murrieta, CA

$60 - $82.25/hr

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 ...

AEVEX

Sr. Stress Engineer

Murrieta, CA · On-site

$200K - $224K/yr

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 ...

AEVEX

Sr. Stress Engineer

Murrieta, CA

$200K - $224K/yr

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 ...

TAD PGS, Inc.

Stress Engineer

San Antonio, TX · On-site

$49.50 - $68/hr

The engineer will collaborate with senior engineers, production teams, quality personnel, and cross ... Examines and analyzes how much stress a structure or component can handle through static, fatigue ...

TAD PGS, Inc

Stress Engineer

San Antonio, TX

$80K - $90K/yr

The engineer will collaborate with senior engineers, production teams, quality personnel, and cross ... Examines and analyzes how much stress a structure or component can handle through static, fatigue ...

Expleo

Stress Engineer - VI - Wichita

Wichita, KS

$90/hr

Wichita, KS Pay Rate: $90.00+/hour EXPLEO GROUP USA is currently looking for a Senior Consultant Stress Engineer (Metallic/Composite, Fuselage, Structure) (Level 6) to join our team for an exciting ...

Expleo

Stress Engineer - VI - Wichita

Wichita, KS

$90/hr

Wichita, KS Pay Rate: $90.00+/hour EXPLEO GROUP USA is currently looking for a Senior Consultant Stress Engineer (Metallic/Composite, Fuselage, Structure) (Level 6) to join our team for an exciting ...

Expleo

Stress Engineer VI - Tulsa

Tulsa, OK

$90/hr

Tulsa, OK Pay Rate: $90.00+/hour EXPLEO GROUP USA is seeking a Senior Consultant Stress Engineer (Level 6) to provide industry-leading expertise, innovation, and strategic technical leadership across ...

Expleo

Stress Engineer VI - Tulsa

Tulsa, OK · On-site

$90/hr

Location: Tulsa, OK Pay Rate: $90.00+/hour EXPLEO GROUP USA is seeking a Senior Consultant Stress Engineer (Level 6) to provide industry-leading expertise, innovation, and strategic technical ...

Knight Aerospace Careers

Stress Engineer II

San Antonio, TX · On-site

$53 - $72.50/hr

We are seeking a Mechanical Stress Engineer with a solid background in aircraft structures ... The engineer will collaborate with senior engineers, production teams, quality personnel, and cross ...

Ag

Static Stress Engineer - Contract

Wichita, KS

$52.50 - $72/hr

As a Static Stress Engineer you will support the fleet in-service repair of aircraft structures and ... Liaise with Principal and Senior Static Engineers in order to ensure that methods, assumptions ...

Airbus

Static Stress Engineer - Contract

Wichita, KS · On-site

$52.50 - $72/hr

As a Static Stress Engineer you will support the fleet in-service repair of aircraft structures and ... Liaise with Principal and Senior Static Engineers in order to ensure that methods, assumptions ...

Boeing

Tooling Stress Engineer

North Charleston, SC · On-site

$103K - $140K/yr

The Boeing Company Boeing Commercial Airplanes (BCA) is seeking a Tooling Stress Engineer (Experienced or Senior) to join the Propulsion South Carolina (PSC) team in North Charleston, SC . The PSC ...

Boeing

Tooling Stress Engineer

North Charleston, SC

$103K - $140K/yr

The Boeing Company Boeing Commercial Airplanes (BCA) is seeking a Tooling Stress Engineer (Experienced or Senior) to join the Propulsion South Carolina (PSC) team in North Charleston, SC . The PSC ...

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Senior Stress Engineer information

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$59.5K

$126.6K

$183.5K

How much do senior stress engineer jobs pay per year?

As of Jul 15, 2026, the average yearly pay for senior stress 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 is the difference between Senior Stress Engineer vs Stress Analyst?

AspectSenior Stress EngineerStress Analyst
Required CredentialsBachelor's or Master's in Mechanical or Aerospace Engineering, Professional Engineer (PE) license often preferredBachelor's or Master's in Mechanical or Aerospace Engineering, relevant certifications beneficial
Work EnvironmentDesign and analysis teams in aerospace, automotive, or defense industries; often involved in complex projectsAnalysis-focused roles within engineering teams, primarily performing stress calculations and simulations
Employer & Industry UsageUsed in aerospace, automotive, and heavy machinery sectors for advanced stress analysisCommon in similar industries, often as entry to mid-level roles supporting senior engineers

While both roles involve stress analysis, Senior Stress Engineers typically lead complex projects, make critical design decisions, and have more experience and certifications. Stress Analysts support these efforts through detailed calculations and simulations. The senior role requires broader expertise and often involves project management responsibilities.

What are some common challenges faced by Senior Stress Engineers in cross-functional project teams?

Senior Stress Engineers often work closely with design, manufacturing, and quality teams to ensure structural integrity of components under various loading conditions. A common challenge is balancing strict safety requirements with tight deadlines and evolving design changes. Effective communication and problem-solving skills are essential for resolving conflicts between design intent and manufacturability, while ensuring compliance with industry standards. Additionally, Senior Stress Engineers are frequently responsible for mentoring junior engineers and providing technical guidance across departments.

What engineers make $300,000 a year?

Senior Stress Engineers in specialized industries such as aerospace, automotive, or energy can earn $300,000 or more annually, especially with extensive experience, advanced certifications, and working in high-demand environments. Compensation often includes bonuses and stock options, reflecting the technical expertise and critical nature of their roles.

What engineer makes $500,000 a year?

Senior Stress Engineers in specialized industries such as aerospace, defense, or oil and gas can earn salaries approaching or exceeding $500,000 annually, especially with extensive experience, advanced certifications, and leadership roles. High compensation often includes bonuses, stock options, or other incentives for senior-level engineers with unique expertise and responsibilities.

What engineers make $200,000 a year?

Senior Stress Engineers in industries such as aerospace, automotive, and energy often earn $200,000 or more annually, especially with extensive experience, specialized skills, and advanced certifications. High salaries are typically associated with roles requiring expertise in finite element analysis, materials science, and proficiency with simulation tools like ANSYS or Abaqus.

What does a senior stress engineer do?

A senior stress engineer analyzes and evaluates the structural integrity of engineering components and systems, often using finite element analysis (FEA) software. They identify potential failure points, develop solutions to improve durability, and ensure designs meet safety standards, typically working closely with design and manufacturing teams. Strong knowledge of materials, stress analysis techniques, and relevant industry certifications are essential for this role.

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

To thrive as a Senior Stress Engineer, you need a strong background in mechanical or aerospace engineering, advanced knowledge of structural analysis, and experience with industry standards, typically supported by a relevant degree. Proficiency with finite element analysis (FEA) software such as ANSYS or NASTRAN, and familiarity with CAD systems and regulatory requirements are essential. Strong analytical thinking, problem-solving abilities, and effective communication skills help you interpret complex data and collaborate with multidisciplinary teams. These skills ensure the safety, reliability, and compliance of structures in high-stakes engineering environments.
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Senior Stress Engineer jobs near you
Infographic showing various Senior Stress Engineer job openings in the United States as of July 2026, with employment types broken down into 95% Full Time, 2% Part Time, and 3% Contract. Highlights an 87% Physical, 4% Hybrid, and 9% Remote job distribution, with an average salary of $126,557 per year, or $60.8 per hour.

Sr. Stress Engineer

AEVEX

Murrieta, CA

$60 - $82.25/hr

Other

Re-posted 13 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.

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