Aerospace Structural Stress Manager (San Diego)

Who We Are

Mammoth Freighters is a leading FAA-certified engineering firm specializing in aftermarket widebody aircraft structural modifications. Our team delivers innovative, airworthiness-approved solutions for commercial and cargo operators worldwide. With a proven track record of successful Supplemental Type Certificates (STCs) and Major Repairs/Alterations (MRAs), we are expanding our structural engineering leadership team in San Diego, CA and Fort Worth, TX.

Pay Ranges:

San Diego, CA: $165,000 - $185,000 DOE

Fort Worth, TX: $145,000 - $165,000 DOE

Job Overview

We are seeking an experienced and highly qualified Structural Stress Manager to lead our structural analysis team in support of FAA-certified aftermarket modifications for widebody commercial aircraft. This individual will serve as the technical authority for all structural stress analysis activities, overseeing a multi-disciplinary team of stress engineers and interfacing directly with FAA, DER, and customer representatives as well as managing the engineering team.

The ideal candidate brings deep expertise in fuselage, floor, and wing structural analysis, a thorough understanding of FAA certification requirements, and a demonstrated ability to manage complex engineering programs from concept through certification.

Job Responsibilities

• Lead and manage a team of structural stress engineers across all phases of FAA-certified widebody aircraft modification programs.
• Serve as the primary technical authority and signatory for structural stress analysis reports and substantiation packages.
• Establish, enforce, and continuously improve structural analysis methodologies, standards, and best practices in alignment with FAA regulations (FAR Part 25, AC 25.571-1, etc.).
• Coordinate with Designated Engineering Representatives (DERs) and FAA Aircraft Certification Office (ACO) personnel to ensure timely and compliant approvals.
• Review and approve all structural substantiation documentation including stress reports, load statements, fatigue and damage tolerance analyses.
• Support STC, Major Alteration, and Engineering Order programs from preliminary design through certification closure.
• Interface with program management, design engineering, manufacturing, and quality assurance teams to maintain schedule and technical integrity.
• Mentor and develop junior stress engineers, providing technical guidance and career development support.
• Participate in program planning, resource allocation, bid support, and technical proposal preparation.

Areas Of Expertise

Fuselage Structure

• Stress analysis of fuselage frames, stringers, skin panels, and pressure bulkheads.
• Evaluation of fuselage cutouts, reinforcements, and doubler installations.
• Pressurization cycle fatigue analysis and damage tolerance assessments per FAR 25.571.
• Analysis of fuselage-mounted systems interfaces including structural brackets and fittings.
• Support for STC modifications involving cargo door installations, passenger-to-freighter (P2F) conversions, and fuselage interior reconfigurations.

Floor Structure

• Analysis of main deck and lower deck floor beams, seat tracks, and floor panels, stanchions.
• Structural evaluation of cargo loading systems including tie-down fittings, PDUs, and ball mat structures.
• Emergency landing load analysis and occupant protection compliance per FAR 25.561 and 25.562.
• Weight and balance impacts from floor structure modifications.
• Fatigue and residual strength analysis for floor beam attachments and surrounding fuselage structure.

Wing Structure

• Static and fatigue stress analysis of wing skins, spars, ribs, and control surface attachments.
• Evaluation of winglet and sharklet installations and associated load redistribution effects.
• Analysis of pylon and engine strut structural interfaces for engine upgrade modifications.
• Fuel system structural interface analysis including vent, boost, and transfer system provisions.
• Aeroelastic and flutter substantiation support for aerodynamic surface modifications.

Job Qualifications

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or closely related field (Master's degree preferred).
• Minimum 10 years of structural stress analysis experience in commercial aviation, with at least 3 years in a senior or lead engineering role.
• Demonstrated experience with FAA Part 25 certification, STC development, and Major Alteration programs.
• Proficiency with industry-standard structural analysis tools:
• Finite Element Analysis (FEA): NASTRAN, ANSYS, ABAQUS
• Classical hand analysis methods (Bruhn, Niu, ESDU)
• Fatigue and damage tolerance tools (AFGROW, NASGRO, or equivalent)
• In-depth knowledge of applicable FARs, ACs, and TSOs including FAR Part 25, AC 25.571-1, and AC 20-107.
• Strong interpersonal and technical communication skills; ability to clearly present complex engineering findings to FAA and customers.

Preferred Qualifications

• Experience with widebody aircraft programs (Boeing 767, 777, 747; Airbus A330, A340, A350).
• Familiarity with FAA certification coordination.
• Experience with P2F (passenger-to-freighter) conversion programs.
• Experience managing engineering teams in an AS9100/ISO 9001 quality environment.

Benefits

• Competitive Salary - Highly competitive salary aligned with market benchmarks, with opportunities for performance-based increases and career growth.
• 401k match – Plan for your future with a company match of up to 3%, 100% vested from day one—so every dollar is yours to keep.
• Comprehensive Benefits – We cover 100% of employee premiums for employee-only medical, dental, and vision plans. Life Insurance and disability coverage are also offered.
• PTO & Work-Life Balance - Generous paid time off and flexible scheduling.
• Impactful Projects - Lead high-profile FAA certification programs with global airline and cargo customers.

Work Location: In person