z21 Ventures
Stress Analysis Engineer - Propulsion
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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.
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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.
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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.
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