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Senior Stress Engineer Jobs (NOW HIRING)

AEVEX

Sr. Stress Engineer

San Diego, 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 ...

Skylimit Systems

Senior Stress Engineer

Houston, TX · On-site

$113K - $145K/yr

This opportunity is ideal for an experienced Senior Stress Engineer who is passionate about structural analysis, composite materials, and solving complex engineering challenges. In this role, you'll ...

Radiant

Senior Stress Engineer

El Segundo, CA · On-site

$133K - $184K/yr

About the Role Radiant is seeking a Stress Engineer to own and execute structural loads, vibration, and dynamic analyses for complex mechanical systems associated for Kaleidos, the world's first ...

Radiant Industries

Senior Stress Engineer

El Segundo, CA · On-site

$120 - $180/hr

About the Role Radiant is seeking a Stress Engineer to own and execute structural loads, vibration, and dynamic analyses for complex mechanical systems associated for Kaleidos, the world's first ...

Cantos Ventures

Senior Stress Engineer

El Segundo, CA · On-site

$90 - $130/hr

About the Role Radiant is seeking a Stress Engineer to own and execute structural loads, vibration, and dynamic analyses for complex mechanical systems associated for Kaleidos, the world's first ...

Radiant Industries

Senior Stress Engineer

El Segundo, CA · On-site

$133K - $184K/yr

About the Role Radiant is seeking a Stress Engineer to own and execute structural loads, vibration, and dynamic analyses for complex mechanical systems associated for Kaleidos, the world's first ...

Skyryse

Senior Stress Analyst

El Segundo, CA · On-site

SENIOR STRESS ANALYST - EL SEGUNDO, CA Skyryse is seeking a Senior Stress Analyst to support the ... Collaborate closely with design engineering, manufacturing, and flight test teams * Support trade ...

Protingent

Senior Stress Analyst

Bellevue, WA · On-site

$56 - $95/hr

Senior Stress Analyst Position Description: Protingent Staffing has an exciting contract Senior ... Work with interdisciplinary team of engineers to establish and optimize nuclear components design ...

Skyryse

Senior Stress Analyst

El Segundo, CA · On-site

SENIOR STRESS ANALYST - EL SEGUNDO, CA Skyryse is seeking a Senior Stress Analyst to support the ... Collaborate closely with design engineering, manufacturing, and flight test teams * Support trade ...

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Senior Stress Engineer information

See salary details

$59.5K

$126.6K

$183.5K

How much do senior stress engineer jobs pay per year?

As of Aug 26, 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 are the key skills and qualifications needed to thrive as a senior stress engineer?

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.

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 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 does a senior stress engineer do?

A senior stress engineer analyzes and evaluates the structural integrity of components and systems to ensure they can withstand operational loads and conditions. They use engineering principles, finite element analysis software, and testing to identify potential failure points and recommend design improvements, often working closely with design and manufacturing teams. This role typically requires strong problem-solving skills, relevant certifications, and experience in materials and stress analysis methods.
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Senior Stress Engineer jobs near you
Infographic showing various Senior Stress Engineer job openings in the United States as of August 2026, with employment types broken down into 94% Full Time, 2% Part Time, and 4% Contract. Highlights an 85% Physical, 6% Hybrid, and 9% Remote job distribution, with an average salary of $126,557 per year, or $60.8 per hour.

Sr. Stress Engineer

AEVEX

San Diego, CA • On-site

$200K - $224K/yr

Full-time

This job post has expired 5 days ago. Applications are no longer accepted.

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.

The Company 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.