Stress Analysis Engineer - Propulsion

Stress Analysis Engineer - Propulsion We usually respond within a week About Us: Greenjets is an innovative engineering company developing high-performance propulsion systems for the aviation market. Our work spans research and development, engine production, aircraft systems, technical integration and flight testing. We are committed to delivering high-grade engineering and best-in-class propulsion for unmanned aircraft. We do things differently. We move fast, we experiment and we adopt technologies that push beyond the current state of the art. Our aim is to go further, faster and more efficiently, while keeping costs competitive. All our propulsion systems are designed, developed and manufactured in the UK. We focus on high quality, reliable and cost effective products supported by a robust, secure and ethical supply chain. About the Job: Greenjets is seeking a Propulsion Stress Analysis & Mechanical Integrity Engineer to ensure the structural integrity, durability, and safety of rotating and static components within small gas turbines and electric ducted fan propulsion systems. This role is central to the product development lifecycle, combining analytical modelling, detailed finite element analysis (FEA) , structural substantiation, and interpretation of test data. You’ll work closely with multidisciplinary engineering teams to shape mechanical integrity requirements and validate designs in a fast-moving SME environment. What You'll Do: Structural & Mechanical Integrity Perform stress, strain and deformation assessments for rotors, stators, shafts, casings, frames, mounts and ducts. Conduct static, dynamic, fatigue, creep, buckling and vibration analyses, including rotor critical speeds and Campbell diagrams. Apply safety margins and failure criteria aligned with turbomachinery integrity principles. Finite Element Analysis Build and run detailed 3D FEA models (using ANSYS, ABAQUS, NASTRAN or equivalent). Execute non-linear, transient and thermo-mechanical simulations and validate models against test data. Rotating Machinery Integrity Assess mechanical behaviour of high-speed rotors in gas turbines and EDF systems. Define overspeed test cases and containment requirements, considering uncontained rotor risk scenarios. Thermal & Thermo-Mechanical Collaborate with thermal and aerothermal engineers to evaluate thermal gradients, distortion and material response. Support Design & Development Provide structural load cases, design constraints, stiffness criteria and feedback to design teams. Support design for manufacturability, including additive manufacturing considerations. Test and Validation Define instrumentation for structural and vibratory testing. Support engine and spin rig test campaigns and analyse strain gauge and vibration data. Certification & Safety Draft structural substantiation documents, compliance evidence and contribute to hazard analyses. Desirable Qualifications, Experience & Attributes: Degree in Mechanical, Aerospace, Materials Engineering, or related discipline. Strong foundation in solid mechanics, fatigue/fracture mechanics, vibration and material behaviour. Proficiency with major FEA tools (ANSYS, ABAQUS, NASTRAN, etc.). Experience with rotating machinery integrity (turbines/fans/compressors). Familiarity with mechanical integrity concepts such as containment, overspeed criteria, lifing and safety margins. CAD interaction experience (SolidWorks, NX, CATIA or similar). Experience with fatigue life prediction tools (nCode, FEMFAT or equivalent). Hands-on attitude, comfortable with testing, troubleshooting and multidisciplinary teamwork. Strong communication skills capable of explaining technical concepts to engineers and stakeholders. Desirable: Experience with micro gas turbines, small turbofan/EDF rotors. Additive manufacturing materials and constraints exposure. Experience supporting structural certification or compliance documentation. Department Engineering - Propulsion Locations Milton Keynes Remote status Hybrid Employment type Full-time About Greenjets At Greenjets we’re rethinking how the world moves through the air. From cutting-edge electric propulsion to autonomous UAV systems, we design and deliver technology that makes aviation quieter, cleaner and more capable. Joining us means working on projects where your ideas have real impact, combining deep engineering expertise with bold design thinking. As a fast-scaling company there are countless opportunities to take ownership and grow, all within a culture that is collaborative, curious and hands-on Founded in 2022 Co-workers Circa 65