Senior Stress Engineer - Integration

Job Title: Senior Stress Engineer – Integration

Your Role and Your Team:

As a Stress Engineer specializing in structural testing, you will play a crucial role in ensuring the structural integrity and performance of our aircraft components. You will work on the test triangle from coupon testing to full-scale testing, developing and executing verification and validation plans. You will collaborate closely with the materials and process team, test team, design team, and stress and fatigue team to ensure comprehensive testing and evaluation.

You will report directly to the Engineering Lead responsible for Structural Integrity Testing within the Structures and Interior Design Organization. This organization is the engineering team within the Lilium engineering organization responsible for the development of the aircraft structure, such as the fuselage or the wing system, as well as the interior of the Lilium Jet. The team supports development across the entire life cycle—from concept through detailed design, testing, and into serial production.

Your Day to Day:

• Design and execute verification and validation testing plans, covering all stages from coupon tests to full-scale tests.
• Manage the testing process from planning to execution.
• Generate test FEM, define test boundary conditions, loading, and instrumentation.
• Prepare and present test requests, technical reports, and test evaluation documentation
• Correlate test results with finite element models (FEM) to ensure accuracy and reliability.
• Conduct detailed stress analysis of aerospace components and systems using advanced analytical methods and software tools, including performing finite element analysis (FEA) to evaluate structural performance and predict the behavior of components under various loading conditions.
• Collaborate with the materials and process team, test team, design team, and stress and fatigue team to provide guidance on material selection, structural design, and optimization.

Your Profile:

• Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or a related field.
• Over 8 years of experience in stress analysis and component-level testing within the aerospace industry.
• Extensive experience in defining Validation and Verification processes for certification and demonstrating compliance with Means of Compliance (MoC) 1 per aircraft certification specifications such as CS 25 and CS 29.
• Solid experience in coupon-level and element-level testing.
• Significant experience with hand calculations, commercial implicit FE codes like OptiStruct or Nastran, and related pre- and post-processing tools (HyperMesh and HyperView). Knowledge of Python is a plus.
• Extensive knowledge of stress, adhering to established standards for metallic and CFRP structures.
• Deep understanding of loading scenarios and the mechanical behavior of aircraft structures.
• Strong understanding of aerospace materials, manufacturing processes, and industry standards.
• Knowledge of damage tolerance, and fatigue analysis methods is an advantage.
• Experience in full-scale testing is an advantage.
• Highly motivated, target-oriented work style with strong analytical problem-solving skills.
• High level of self-reliance and an autonomous, goal-driven approach to work.
• Effective communication and teamwork abilities.
• Fluent in English; proficiency in German or other languages is an advantage.