Liaison Stress Engineer

Who We Are

Mammoth Freighters is a leading FAA-certified engineering firm specializing in aftermarket widebody aircraft structural modifications. Our team delivers innovative, airworthiness-approved solutions for commercial and cargo operators worldwide. With a proven track record of successful Supplemental Type Certificates (STCs) and major repairs/alterations, we are expanding our structural engineering support team.

Job Overview

We are seeking an aircraft liaison stress engineer to serve as the primary technical authority between our manufacturing operations and the structural design organization on the 777-200LR/-300ER freighter conversion program. In this role, you will perform real-time stress analysis and structural disposition of manufacturing nonconformances and deviations, ensuring all departures from nominal design are assessed for structural adequacy and airworthiness compliance in accordance with FAA regulations and internal certification standards.

This position demands deep expertise in aircraft structural analysis, a thorough understanding of 777 design intent, and the ability to make engineering judgments under schedule pressure on the production floor.

Job Responsibilities

• Perform stress analysis and structural dispositions of nonconformances (NCRs), engineering deviations, and supplier discrepancies on 777 metallic and composite structures.
• Author and approve Engineering Orders (EOs), Deviation Requests (DRs), and Engineering Service Requests (ESRs) within delegated authority limits.
• Interface directly with DER/DAR representatives, FAA designees, and the Designated Engineering Representative network to obtain regulatory approval for major repairs and alterations.
• Conduct detailed hand calculations and FEA correlation to substantiate structural adequacy of repaired or deviated structure to limit and ultimate load requirements.
• Collaborate with manufacturing, quality assurance, and tooling teams to develop practical repair schemes that preserve fatigue life and damage tolerance requirements per FAR Part 25.
• Provide on-call floor support during production build phases and aircraft delivery.
• Mentor junior stress engineers and review their analyses, fostering technical and engineering judgment development.
• Maintain and contribute to the stress report, repair manuals (SRM), and structural substantiation documentation.

Required Job Qualifications

• B.S. in Aerospace, Mechanical, or Civil Engineering (M.S. preferred).
• 8 years of structural stress analysis experience in commercial or military aviation.
• Demonstrated 777 or equivalent widebody program experience.
• Proficiency in classical stress methods: beam theory, thin-walled sections, bolted/riveted joint analysis, composite laminate theory.
• Hands-on experience with FEA tools (FEMAP, NASTRAN, or equivalent).
• Familiarity with FAR Part 25 certification basis and AC 25.571 damage tolerance requirements.
• Experience authoring and approving dispositions.
• Strong written and verbal technical communication skills.

Preferred Job Qualifications

• Experience with widebody aircraft programs (Boeing 767, 777, 747; Airbus A330, A340, A350).
• Familiarity with FAA certification coordination.
• Experience with P2F (passenger-to-freighter) conversion programs.
• Experience managing engineering teams in an AS9100/ISO 9001 quality environment.
• Knowledge of 7000- and 2000-series aluminum alloys, titanium, and CFRP repair practices.
• Prior liaison engineering role on a high-rate production program.
• Experience with fatigue and fracture mechanics substantiation.
• History of collaboration with airline customers on in-service structural issues.

Benefits

• Competitive Salary - Highly competitive salary aligned with market benchmarks, with opportunities for performance-based increases and career growth.
• 401k match – Plan for your future with a company match of up to 3%, 100% vested from day one—so every dollar is yours to keep.
• Comprehensive Benefits – We cover 100% of employee premiums for employee-only medical, dental, and vision plans. Life Insurance and disability coverage are also offered.
• PTO & Work-Life Balance - Generous paid time off, flexible scheduling, and hybrid work options where applicable.
• Impactful Projects - Lead high-profile FAA certification programs with global airline and cargo customers.

Education:

Bachelor's (Preferred)

Experience:

Structural stress analysis experience in aviation: 8 years (Preferred)

Work Location: In person