EXPLEO GROUP USA is currently looking for a Stress Engineer (Metallic/Composite, Fuselage Structures) Level 4/5 to join our team for an exciting new opportunity in Wichita, Kansas.
The Stress Engineer will support current and upcoming commercial aircraft structural engineering programs by performing detailed stress analysis and structural substantiation activities for metallic and composite fuselage structures. This role will work closely with design engineering, manufacturing, suppliers, and customer teams to support design changes, production-related activities, and certification efforts while ensuring compliance with aerospace industry standards and customer requirements.
Responsibilities
Structural Analysis & Substantiation
- Plan, organize, and prioritize engineering activities based on project schedules and deliverables.
- Perform detailed stress analysis of metallic and composite aircraft fuselage structures using classical hand calculations and finite element methods.
- Support structural design changes through comprehensive analysis and substantiation.
- Evaluate structures for static strength, fatigue, and damage tolerance requirements.
- Review and analyze engineering design changes and assess structural impacts.
- Generate stress substantiation reports and technical documentation.
- Develop and review structural qualification and certification plans in accordance with customer and regulatory requirements.
- Support production-related engineering activities and resolve structural issues impacting manufacturing and assembly operations.
Technical Coordination & Engineering Support
- Review and approve vendor drawings, stress reports, and test documentation as required.
- Coordinate with design engineers, technical leads, suppliers, manufacturing teams, and program management to ensure timely project execution.
- Participate in design reviews and provide technical recommendations on structural solutions.
- Present technical findings and challenge design approaches when appropriate to ensure optimal structural performance.
- Track and communicate project status, risks, and deliverable completion through progress reporting.
Continuous Improvement & Program Support
- Support engineering process improvements and best-practice initiatives.
- Ensure compliance with customer engineering methods, tools, procedures, and quality requirements.
- Demonstrate strong accountability, urgency, and commitment to delivering high-quality engineering solutions.
Qualifications
- Bachelor's Degree in Aerospace Engineering, Mechanical Engineering, Structural Engineering, or a related discipline.
- 8+ years of aerospace stress engineering experience.
- 7+ years of experience supporting Boeing aircraft programs.
- Experience performing stress analysis on both metallic and composite aircraft structures.
- Strong knowledge of aircraft fuselage structures and structural analysis methodologies.
- Experience with static analysis, finite element analysis, and free-body diagram calculations.
- Proficiency using: Nastran, Patran, Abaqus
- Strong understanding of: Engineering Mechanics, Strength of Materials, Aircraft Structural Analysis, Structural Substantiation Processes
- Proficiency with Microsoft Excel, Word, PowerPoint, and Project.
- Excellent communication and cross-functional collaboration skills.
- Boeing tools, methods, processes, and engineering standards knowledge
- Experience supporting Boeing commercial aircraft programs, including 737 programs.
- Fuselage engineering experience with preference given to candidates with floor structure experience.
- Production support engineering experience.
- Fatigue & Damage Tolerance (F&DT) experience is a plus but not required.
- Recognized technical expertise within aerospace structural analysis.
What We Offer
At Expleo Group USA, we value expertise, innovation, and collaboration. By joining our client's team, you'll work on high-impact aerospace programs while enjoying a supportive and technically engaging work environment.
- Competitive Compensation – $70 - $90 per hour. Final compensation is determined based on skill alignment, years of experience, and fair, market-based rates by geography.
- Comprehensive Benefits for you and your dependents – Extensive Medical Plans, Dental, Vision, HSA with company contribution, company-sponsored Life Insurance and Short- and Long-Term Disability Insurance, a host of voluntary plans including legal, hospital, accident, pet wellness, and 401(k) with company matching.
- Paid Holidays and Paid Time Off
- Career Development and Advancement – Expleo is a global company operating in 29 countries worldwide with a strong focus on employee development and career growth.
- Strong Team Culture – Collaborate with experienced professionals who value precision, technical excellence, innovation, and teamwork.
About Expleo
Expleo is a global engineering, technology, and consulting service provider with 18,000 employees across more than 30 countries. Since 1966, we have partnered with leading organizations in Aerospace, Automotive, Rail, Healthcare, Energy, and other high-tech industries, delivering end-to-end engineering, production support, MRO, and quality services.
Learn more at www.expleogroup.com
This position may require access to information subject to U.S. export-control regulations (e.g., ITAR/EAR). Employment is contingent upon the ability to obtain such access. Under these regulations, access may be limited to U.S. Persons, including U.S. citizens, lawful permanent residents (green card holders), and individuals granted refugee or asylee status.
Expleo is an equal opportunity employer. We are committed to non-discrimination throughout all stages of the recruitment process and ensure fair and unbiased hiring practices. Qualified applicants will be considered without regard to race, color, religion, sex (including pregnancy), sexual orientation, gender identity, national origin, age, disability, genetic information, or any other protected characteristic protected by applicable law.
