Stress Engineer
Sarla Aviation
Other Engineering
Bengaluru, Karnataka, India
Posted on Apr 7, 2026
About Sarla Aviation:
Sarla Aviation is at the forefront of revolutionizing urban air mobility with its cutting-edge eVTOL (electric Vertical Take-off and Landing) aircraft featuring innovative tilt-rotor technology. Sarla Aviation, a pioneer in the development of sustainable, efficient, and safe air transportation systems, is dedicated to influencing the future of aviation.
About the Role:
We are seeking a highly motivated Stress Engineer to join our Airframes team. In this role, you will be responsible for the structural analysis and validation of airframe components, ensuring our aircraft meets safety, performance, and certification requirements. You will work at the intersection of design, analysis, and testing, contributing to efficient, lightweight, and robust structures. This is a chance to shape not only our aircraft but the future of air mobility.
What You'll Do
- Perform structural analysis of airframe components and assemblies using classical hand calculations and finite element methods (FEM)
- Develop, validate, and maintain finite element models using HyperMesh, Simcenter 3D, and NX Nastran
- Analyse metallic and composite structures (CFRP, GFRP where applicable), identifying load paths, stress concentrations, and failure modes
- Perform joint analysis for fastened and bonded connections in metallic and composite assemblies
- Analyse structural interfaces with propulsion systems, including motor mounts and rotor hubs, considering dynamic and vibratory loading environments
- Assess structural integration of battery enclosures, including crash load paths and compatibility with thermal runaway containment requirements
- Support fatigue and damage tolerance (F&DT) assessments for both metallic and composite structures in accordance with certification requirements
- Support structural sizing and optimisation, working closely with design engineers to improve weight, strength, and manufacturability
- Conduct trade studies and support design iterations through data-driven analysis
- Investigate and resolve manufacturing non-conformities, providing timely and practical engineering solutions
- Contribute to test definition and execution (static and fatigue), and correlate test results with analytical models
- Generate clear, traceable stress reports to support internal reviews and certification documentation
- Collaborate closely with Structures, Design, Manufacturing, and Test teams to ensure continuous improvement and design convergence
- Support development and improvement of internal analysis methods, tools, and processes
What You'll Need
- Bachelor's or Master's degree in Aerospace, Mechanical Engineering, or a related field
- 3–5 years of experience in structural/stress analysis (aerospace or similar industry preferred)
- Strong foundation in hand calculations and FEM-based structural analysis
- Hands-on experience with HyperMesh, Simcenter 3D, and NX Nastran (FEA solver); familiarity with NX CAD is advantageous
- Good understanding of metallic and composite structural behaviour and failure mechanisms, including residual stress effects post-cure
- Familiarity with airworthiness and certification requirements
- Experience with fatigue and damage tolerance (F&DT) methodology for metallic and composite structures
- Experience performing joint analysis for fastened and bonded structural connections
- Strong problem-solving skills with solid engineering intuition for load paths and structural response
- Effective communicator, able to work across multi-disciplinary teams in a fast-paced, evolving development environment
- Strong documentation and reporting skills
Nice To Have
- Experience with GFEM (Global Finite Element Model) development or model correlation
- Exposure to vibration, modal, or dynamics-related analyses
- Understanding of aeroelastic effects on lifting surfaces and rotor blades
- Awareness of thermal effects on composite structures, including process-induced deformation (PID) and post-cure residual stress
- Knowledge of composite manufacturing processes (layup, draping, filament winding) and their structural implications
- Experience supporting structural testing and test-analysis correlation activities
- Familiarity with advanced Simcenter modules
- Basic scripting or automation skills (Python, MATLAB) for analysis workflow development
- Strong communication, documentation, and organizational skills.
- Entrepreneurial mindset with ability to work in a startup environment.
Why Join Us?
Be a part of a world-class team in an environment where your work directly contributes to shaping the future of urban air mobility.
Thrive in our culture of diversity, inclusion, and innovation, where your unique perspectives and ideas are valued.
Enjoy a competitive compensation package, with opportunities for growth and development in a rapidly evolving industry.
Sarla Aviation is dedicated to creating a diverse and inclusive workspace, championing equality and empowering every individual. We believe that our strength lies in our differences, not just our similarities. Therefore, we warmly welcome applications from all qualified candidates, regardless of their ethnicity, gender, disability, religion, sexual orientation, or age. Join us at Sarla Aviation, where your unique background and perspective are not just welcomed—they are celebrated.