Stress Analysis Engineer, Maritime Structures

ABOUT THE TEAM

The Maritime Manufacturing Technology team is responsible for rapidly developing and implementing manufacturing technologies and processes for cutting-edge defense hardware, including deployable static and moving surface, undersea and sea to air vehicles and scaling these products in our new manufacturing facilities.

ABOUT THE JOB

We are looking for a Stress Analysis Engineer to join our rapidly growing team in Santa Ana, CA to lead stress analysis, materials characterization, and design allowables development for mission-critical maritime and subsea hardware. In this role, you will be the foundational structural authority bridging the gap between classical stress analysis, finite element modeling (FEM), and Materials & Processes (M&P) metallurgy.

You will own the structural integrity of advanced pressure-boundary enclosures, launch systems, and high-consequence maritime structures from clean-sheet architecture through fabrication and qualification testing. This is an individual contributor role with high autonomy and the opportunity to scale into a technical capability lead as the product line expands.

WHAT YOU’LL DO

• Structural Analysis & Sizing: Perform classical hand calculations (first-principles, Roark, Bruhn) and advanced Finite Element Analysis (FEA) including linear, non-linear, buckling, fatigue, and fracture mechanics on complex maritime pressure boundaries, structural enclosures, and mechanism assemblies.
• Material Allowables & Characterization: Define, build, and maintain statistical structural design allowables (A- and B-basis) across primary metallic and composite materials. Define coupon-level test matrices to characterize tensile strength, fatigue, fracture toughness, and environmental degradation.
• Allowables Database Ownership: Serve as the custodian of the centralized allowables database across engineering teams, establishing clear thresholds for requalification when processing, vendor sources, or material lots change.
• M&P and Metallurgy Integration: Act as the primary analysis interface to Materials & Processes (M&P) and Manufacturing Engineering. Translate material specifications, heat treatments, and weld joint efficiencies (WPS/PQR) into actionable finite element models and structural margin calculations.
• Manufacturing Impact & Dispositions: Account for manufacturing-induced effects—including residual stresses, weld shrinkage/distortion, and surface finishes—in structural assessments. Provide rapid, quantitative stress dispositions for non-conformances, deviations, and material anomalies.
• Test Campaign Execution: Drive structural test programs from coupon-level mechanical testing to full-scale subcomponent qualification. Partner directly with internal test teams and external mechanical testing facilities to scope, schedule, and execute test plans.

REQUIRED QUALIFICATIONS

• Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, Structural Engineering, Materials Science, or a related technical discipline.
• 4+ years (Mid) or 7+ years (Senior) of demonstrated experience in structural stress analysis on high-consequence hardware (aerospace, defense, marine/subsea, or space systems).
• Deep proficiency in both classical hand calculations and commercial FEA tools (e.g., Abaqus, ANSYS, Nastran/Patran, or HyperMesh).
• Practical experience developing design allowables using statistical methods (e.g., MMPDS methodologies) and working closely with metallurgy/materials teams on alloy selection, heat treatments, and welded joint efficiencies.
• Strong understanding of heavy metallic fabrication processes (machining, forging, casting, welding) and their influence on fatigue life and structural margins.
• Demonstrated ability to manage competing priorities, interface with cross-functional design and manufacturing teams, and wear multiple technical hats to drive hardware across the finish line.
• Must be a U.S. Person due to required access to U.S. export controlled information or facilities.
• Eligible to obtain and maintain an active U.S. Secret security clearance.

PREFERRED QUALIFICATIONS

• Prior experience with maritime, subsea, or pressure-vessel structural design (NAVSEA criteria, ASME Section VIII, ABS rules, or deep submergence standards).
• Working knowledge of fatigue and fracture mechanics software (e.g., NASGRO) and damage-tolerance methodologies.
• Hands-on experience coordinating with external mechanical and environmental testing laboratories.
• Familiarity with modern CAD platforms (NX, Creo, SolidWorks) and automated scripting for analysis post-processing (Python, MATLAB).
• Active U.S. DoD Secret or Top Secret clearance.