Staff Stress Methods Engineer

Archer Aviation is seeking a highly motivated, experienced engineer to join our team in revolutionizing the aviation industry. In this role you will be developing predictive Finite Element Analysis (FEA) methods, advanced material models and analysis tools. You will bridge the gap between physical testing and virtual simulation by collecting test data, calibrating material models, and demonstrating high-fidelity correlation at both the component and system levels. This role is critical in enabling vehicle-level predictive simulations that reduce the need for iterative physical testing and accelerate our path to certification.

Responsibilities

• Establish and document best practices for a Building Block Approach to structural validation, ranging from coupon-level to full-scale vehicle airframes.
• Lead testing efforts to characterize basic material properties and complex interactions within larger systems.
• Develop predictive modeling methods for complex material behavior including plasticity, high strain rates, environmental conditions, and failure.
• Demonstrate test vs. simulation correlation across the Building Block Pyramid for a diverse range of load cases, including modal, static, linear/explicit dynamic, thermal, random vibration, and shock.
• Collaborate with the broader structural analysis team to improve internal analysis methods and software tools.

Qualifications

Required:

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, or a related field.
• 5+ years of professional experience in finite element modeling.
• Expert-level proficiency in ANSYS, NASTRAN, or similar FE software.
• Deep understanding of the Finite Element Method (FEM) and material behavior including plasticity and failure theories.
• Experience with modeling complex material behavior and generating material cards for analysis. 
• Familiarity with measurement tools (strain gauges, load cells, extensometers, accelerometers, digital image correlation etc) and mechanical testing equipment (load frames, shaker tables, drop towers).
• Strong technical, written, and verbal communication skills

Preferred:

• Master’s or PhD in Aerospace or Mechanical Engineering.
• Experience with NX, ANSA, Meta, HyperX, or NCODE.
• Proficiency in Python or Matlab for automating simulation workflows and post-processing.
• Experience with composite materials, metallic fatigue and adhesive bond failure.
• Experience with high strain rate material testing.
• Materials database management. 

At Archer we aim to attract, retain, and motivate talent that possess the skills and leadership necessary to grow our business. We drive a pay-for-performance culture and reward performance that supports the Company’s business strategy. For this position we are targeting a base pay between $152,000- $190,000. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.

This position will require travel up to 10% to Archer facilities or supplier facilities.

Archer is committed to working with and providing reasonable accommodations to job applicants with physical or mental disabilities, and those with sincerely held religious beliefs. Applicants who may require reasonable accommodation for any part of the application or hiring process should provide their name and contact information to Archer’s People Team at [email protected]. Reasonable accommodations will be determined on a case-by-case basis.