Manufacturing Finite Element Analyst

Position Overview

We are seeking a Finite Element Analyst to support the development, industrialization, and manufacturing of large composite aerospace structures. This role will focus on applying finite element analysis (FEA) to manufacturing-driven engineering problems and supporting the rapid transition of composite structures from design through tooling, process development, qualification, production ramp, and sustaining manufacturing. 

The ideal candidate combines strong structural analysis fundamentals with practical knowledge of composite structures and manufacturing. This is a hands-on engineering role working closely with Composite Product Engineering, Process Engineering, Tooling, Materials, NDT, Quality, and Production.

Key Responsibilities:

• Develop and execute finite element models of large CFRP monolithic and sandwich structures, including cylindrical shells, beams, panels, bonded assemblies, and structural interfaces.
• Support NCR/MRB activities by providing timely analytical assessment and technical substantiation for use-as-is, rework, and repair dispositions.
• Support manufacturing-driven structural definition and Design for Manufacturing (DFM) trade studies by evaluating alternative geometries, laminate configurations, joints, interfaces, and manufacturing concepts.
• Analyze composite laminates using appropriate orthotropic material models, ply definitions, failure criteria, and sandwich/core representations.
• Perform linear and nonlinear static, buckling, contact, local stress, stiffness, and stability analyses as required.
• Evaluate manufacturing and assembly load cases, including tooling support, lifting and handling, transportation, fixturing, clamping, drilling, bonding, and assembly operations.
• Perform thermal and thermo-mechanical analyses associated with composite manufacturing processes, including tool/part CTE mismatch, thermal gradients, spring-in/spring-back, distortion, and dimensional stability.
• Analyze composite tooling and fixtures, including mandrels, bond fixtures, drill/trim fixtures, handling fixtures, and large manufacturing tools for stiffness, deformation, thermal behavior, and load capability.
• Support dimensional-control and tolerance activities by evaluating the effects of tooling deformation, manufacturing loads, thermal effects, and structural flexibility on final part geometry.
• Evaluate manufacturing nonconformances and proposed repairs, including thickness deviations, laminate defects, disbonds, machining damage, holes, inserts, bonded doublers, and other manufacturing-induced conditions.
• Develop local/global models and submodels as required to accurately evaluate manufacturing defects, geometric discontinuities, interfaces, and local stress concentrations.

Qualifications

Education:

• Bachelor’s degree in mechanical engineering, Aerospace Engineering, Structural Engineering, or a related technical discipline.

Experience:

• 3+ years of finite element analysis experience in aerospace, composites, or other high-performance structural applications.
• Strong experience with commercial FEA tools such as Abaqus, ANSYS, Nastran/Patran, Simcenter 3D/NX Nastran, or equivalent.
• Ability to work in a fast-paced manufacturing environment and provide timely, technically sound engineering recommendations.
• Strong technical communication and documentation skills

Preferred Qualifications: 

• Experience with large aerospace composite shells, cylinders, beams, panels, or sandwich structures.
• Experience with NX/Simcenter, Fibersim and FEMAP.
• Experience supporting manufacturing NCR/MRB dispositions and composite structural repairs.
• Familiarity with composite coupons, element, and structural testing and correlation of FEA predictions with physical test results.

Soft Skills:

• Strong communication skills and the ability to work cross-functionally with engineering, quality, and production.
• Excellent technical writing and documentation capabilities.
• Highly skilled in troubleshooting complex manufacturing challenges.
• Strong attention to detail and a commitment to high-quality results.
• Effective organizational and project management abilities.

Technology Stack:

• Experience with FEA tools such as Abaqus, ANSYS Nastran/Patran, Simcenter 3D/NX Nastran, or equivalent
• Experience with NX/Simcenter, Fibersim and FEMAP

Physical Requirements

• Ability to work in a manufacturing environment.

This job description may not be inclusive to the duties and responsibilities listed. Additional tasks may be assigned to the employee from time to time or the scope of the job may change as needed by business demands.