Stress Engineer

Job Title : Sr. Stress Engineer

Location : Mississauga, Ontario (On-site)

Duration : Fulltime

Position Summary:

• Seeking highly skilled and experienced Stress Engineering Specialists to support the structural analysis and certification of both new and existing aircraft programs. The successful candidate will have 10+ years of experience in aerospace stress engineering, with advanced proficiency in Finite Element Modelling (DFEM and GFEM), classical hand calculations, and a wide range of analysis tools and techniques.
• This role offers the opportunity to work on high-impact programs, where analytical excellence and engineering judgment are key to ensuring the structural integrity, safety, and regulatory compliance of De Havilland’s aircraft.

Key Responsibilities:

• Perform detailed and global finite element analysis (DFEM and GFEM) to support structural design, modifications, and certification.
• Execute and validate classical hand calculations for static strength, fatigue, and damage tolerance analysis.
• Analyze structural components including fuselage, wings, empennage, nacelles, landing gear attachment areas, and interiors.
• Collaborate with Design, Loads, Materials, and Liaison Engineering to ensure structural integrity and manufacturability of designs.
• Prepare and review engineering documentation, including stress reports, substantiation packages, and compliance matrices.
• Support certification efforts with regulatory agencies (TCCA, FAA, EASA), including coordination with Design Approval Representatives (DARs).
• Assist in the development and maintenance of analysis tools, templates, and best practices for stress calculations.
• Provide mentorship and technical leadership to junior engineers and analysts.

Qualifications:

• Bachelor’s or Master’s degree in Aerospace, Mechanical Engineering, or a related field.
• 10+ years of progressive experience in aircraft structural stress analysis.
• Expertise in FEM tools such as NASTRAN, Patran, HyperMesh, FEMAP, or ANSYS.
• Strong experience with DFEM and GFEM modelling, mesh refinement, boundary conditions, and results interpretation.
• Proficient in hand calculations using classical methods (Bruhn, Niu, Roark, etc.).
• Comfortable using spreadsheets, scripting tools (e.g., Python, MATLAB), and custom calculation tools.
• Solid understanding of certification requirements, including fatigue and damage tolerance criteria per FAR/CS Part 25.
• Experience preparing substantiation reports and interacting with certification authorities or DERs.
• Excellent communication, documentation, and problem-solving skills.

Preferred Qualifications:

• Familiarity with legacy aircraft structure and modification/repair analysis.
• Experience in weight optimization, composite structure analysis, or crashworthiness is an asset.
• Knowledge of PLM systems (e.g. ENOVIA, SmarTeam) and configuration control processes.

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