FEA (Finite Element Analysis) or CAE (Computer-Aided Engineering)

GENERAL JOB SUMMARY:

The FEA / CEA Engineer is responsible for performing structural, thermal, vibration, fatigue, and computational engineering analysis in support of the design, development, qualification, and production of aerospace propulsion systems and components.

This position works closely with Design Engineering, Product Engineering, Manufacturing, Quality, Test, and Program Management to validate designs, identify technical risks, resolve hardware issues, and ensure products meet performance, reliability, manufacturability, and customer requirements.

The ideal candidate is a hands-on engineer capable of translating analytical results into practical engineering decisions and supporting hardware from initial concept through testing and production.

Essential Duties and Responsibilities

Structural & Multiphysics Analysis

• Develop and perform finite element and computational analyses for aerospace components, assemblies, and propulsion systems.
• Perform linear and nonlinear structural analysis, including stress, strain, deformation, contact, and load-path evaluations.
• Conduct thermal and thermal-stress analysis for components operating in high-temperature environments.
• Perform modal, vibration, harmonic, and dynamic response analysis as required.
• Evaluate component fatigue life, durability, fracture risk, and structural margins.

Analysis Modeling, Verification & Design Substantiation

• Develop appropriate analytical models, assumptions, boundary conditions, material properties, loading conditions, and acceptance criteria.
• Perform mesh development, convergence studies, sensitivity studies, and model verification.
• Calculate and document Factors of Safety and Margins of Safety against applicable design requirements.
• Support rotating-component analysis including shafts, turbine components, bearings, housings, and other propulsion-system hardware.

Test Correlation & Validation

• Correlate analytical predictions with component, subsystem, and engine test results.
• Support instrumentation and test planning required to validate analytical models.
• Support Design Reviews, DFMEA/PFMEA activities, qualification testing, First Article Inspection, and production readiness.

Failure Investigation & Corrective Action

• Perform root-cause analysis of component failures, test anomalies, nonconformances, and field-return hardware.
• Support RCCA, FRACAS, NCR, and corrective-action activities with engineering analysis and supporting data.
• Evaluate supplier-manufactured components when dimensional, material, or manufacturing conditions deviate from engineering requirements.
• Provide technical disposition recommendations for nonconforming hardware when supported by engineering analysis.

Design Engineering & Product Development Support

• Provide analysis supporting design changes, configuration changes, ECOs, and product improvements.
• Work directly with Design Engineering to optimize geometry, materials, tolerances, weight, performance, and durability.

Technical Documentation & Continuous Improvement

• Define and develop modeling and simulation best practices and techniques
• Develop concise engineering reports documenting assumptions, methods, results, conclusions, risks, and recommendations.
• Maintain analysis files, models, calculations, and technical documentation in accordance with configuration-management requirements.
• Support continuous improvement of engineering analysis methods, tools, templates, standards, and validation processes.

Technical Areas of Responsibility

The position may support analysis involving:

• Turbine and rotating components
• Shafts and rotor systems
• Compressor and turbine structures
• Engine housings and cases
• Bearings and bearing-support structures
• Welded and joined assemblies
• High-temperature materials
• Cast, machined, and additive-manufactured components
• Fasteners and mechanical joints
• Thermal interfaces
• Vibration and resonance
• Fatigue and durability
• Structural integrity
• Test fixtures and production tooling
• Assembly contact
• Hyperelastic materials

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Engineering Mechanics, or related engineering discipline.
• 3 years of experience performing finite element, structural, thermal, or computational engineering analysis.
• Demonstrated experience developing and interpreting FEA models.
• Strong understanding of:
• Linear and non-linear analysis techniques
• Implicit and explicit analysis techniques
• Solid mechanics
• Stress analysis
• Contact analysis
• Material behavior
• Heat transfer
• Fatigue
• Vibration
• Engineering mechanics
• Experience with industry-standard FEA/CAE software such as ANSYS, Abaqus, NASTRAN, HyperMesh, or equivalent.
• Ability to independently establish loads, boundary conditions, material properties, contacts, constraints, and appropriate modeling assumptions.
• Ability to interpret engineering drawings, GD&T, specifications, and material requirements.
• Strong analytical problem-solving and technical-report-writing skills.
• Ability to work collaboratively across Engineering, Manufacturing, Quality, Supply Chain, Test, and Program Management.

Preferred Qualifications

• Master's degree in Mechanical, Aerospace, or Engineering Mechanics.
• Experience with gas turbine engines, propulsion systems, turbomachinery, or rotating equipment.
• Experience performing:
• Nonlinear analysis
• Contact analysis
• Thermal-mechanical analysis
• Modal and vibration analysis
• Fatigue/life analysis
• Rotor-dynamic analysis
• Fracture mechanics
• Hyperelastic sealing analysis
• Experience correlating analytical models with physical test data.
• Experience supporting component and engine qualification testing.
• Familiarity with aerospace material properties and temperature-dependent material behavior.
• Experience supporting failure investigations and root-cause analysis.
• Working knowledge of AS9100, configuration management, DFMEA, PFMEA, FRACAS, and aerospace qualification practices.
• Familiarity with MATLAB, Python, or similar engineering-analysis tools.
• Experience in a fast-paced aerospace, defense, propulsion, automotive, or advanced-manufacturing environment.

Key Competencies

• Analytical rigor and engineering judgment
• Strong mechanical aptitude
• Problem solving and root-cause analysis
• Technical communication
• Design and test collaboration
• Attention to analytical assumptions and model validity
• Ability to balance analytical sophistication with practical engineering needs
• Bias toward hardware validation and data-driven decisions
• Ability to work effectively in a rapidly developing production environment

WORK ENVIRONMENT / PHYSICAL REQUIREMENTS

• Office, laboratory, and manufacturing environments
• Interaction with production hardware and test equipment
• Ability to work in manufacturing areas and test facilities
• May be required to lift materials or components up to 50 lbs

TRAVEL REQUIREMENTS

• 0-15% as required to support supplier visits, testing, or program activities

THE ABOVE STATEMENTS ARE INTENDED TO DESCRIBE THE GENERAL NATURE AND LEVEL OF WORK BEING PERFORMED BY INDIVIDUALS ASSIGNED TO THIS CLASSIFICATION. THEY ARE NOT INTENDED TO BE CONSTRUED AS AN EXHAUSTIVE LIST OF ALL RESPONSIBILITIES, DUTIES AND SKILLS REQUIRED OF PERSONNEL SO CLASSIFIED.

A REVIEW OF THIS CLASSIFICATION HAS EXCLUDED THE MARGINAL FUNCTIONS OF THE CLASSIFICATION THAT ARE INCIDENTAL TO THE PERFORMANCE OF FUNDAMENTAL JOB JUTIES. ALL DUTIES AND RESPONSIBILITIES ARE ESSENTIAL JOB FUNCTIONS AND REQUIREMENTS AND ARE SUBJECT TO POSSIBLE MODIFICATION TO REASONABLY ACCOMMODATE INDIVIDUALS WITH DISABILITIES TO PERFORM THIS JOB PROFICIENTLY. THE REQUIREMENTS LISTED IN THIS DOCUMENT ARE THE MINIMUM LEVELS OF KNOWLEDGE, SKILLS OR ABILITIES.

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