Senior Stress & Thermomechanical FEA Engineer - Propulsion Battery System (all genders)

Your Mission:

As Senior Stress & Thermomechanical FEA Engineer – Propulsion Battery System (all genders) you will join VÆRIDION’s Technology division within the Mechanical Design & Integration team and lead the structural, stress, and thermomechanical finite element analysis (FEA) of the propulsion battery system for VÆRIDION’s CS-23 all-electric aircraft.

You will own the computational modelling of battery packs, power distribution units (PDUs), and their internal hardware, predicting how every component behaves under nominal and emergency conditions – including thermal runaway, the DO-160 environmental qualification conditions applied to the pack and PDU as airborne equipment (temperature and altitude, temperature variation, humidity, operational shocks and crash safety, and vibration), flight loads, and durability over service life. Your analysis will provide engineering evidence that the propulsion battery system is structurally robust, thermally safe, and certifiable.

Within the Mechanical Design & Integration team, you will collaborate with Mechanical Design, Materials & Processes, Test, HV Electrical Systems, Airborne Electronics, Thermal Systems, Aircraft Structures, Certification, Safety, and Quality teams to define analysis methods, apply the material property allowable required for your analyses, and substantiate the qualification of the propulsion battery pack and PDU. You will be the structural and thermomechanical analysis authority for the propulsion battery system, responsible for checking and releasing design against the applicable stress and thermomechanical requirements.

Your work will directly contribute to the propulsion battery system that underpins VÆRIDION’s mission to bring electric flight to regional aviation.

Your Day-to-Day:

• Lead the structural, stress, and thermomechanical FEA of propulsion battery packs, PDUs, and their internal components, predicting how they behave under nominal operation and emergency conditions – including thermal runaway, the DO-160 environmental qualification conditions, and flight and inertial loads.

• Perform room-temperature and elevated-temperature analysis of composites (including sandwich structures), metals, adhesives, and mechanical fasteners, capturing temperature-dependent material behaviour.

• Build and correlate nonlinear models covering material, geometric, and contact nonlinearity – including cohesive-zone and VCCT delamination, composite progressive failure and damage propagation, metal plasticity and rate-dependent behaviour, crushable foam plasticity and densification, large-deformation and post-buckling response, and frictional contact with bolt pretension, including bearing behaviour at fastener holes (bearing yield, hole elongation, and bearing–bypass interaction).

• Model the hyper-elastic and viscoelastic behaviour of potting compounds, gap fillers, foams, gaskets, seals, and thermal interface materials to predict contact pressure and interface integrity across the life of the pack.

• Perform durability and life analysis across the differing service lives of components within the system, covering vibration-induced high-cycle fatigue (DO-160 random and sine sweep), low-cycle fatigue from ground–air–ground and charge/discharge thermal cycling, and fatigue of bonded joints, fasteners, busbars, and interconnects.

• Assess creep and stress relaxation of seals, adhesives, polymers, potting compounds, and thermal interface materials at elevated temperature, including loss of contact pressure across a pack replacement interval.

• Analyse thermal runaway response as a coupled thermomechanical event – pressure loads, direct impingement flow, ejecta, and heat transfer to surrounding structure and systems – working closely with the Thermal Systems team on thermal runaway CFD modelling and the resulting heat transfer boundary conditions, in support of containment and continued safe flight and landing.

• Apply static, fatigue, and creep material property allowable (room and elevated temperature) in the substantiation of the propulsion battery pack and PDU, working to established methodologies such as CMH-17 for composites and MMPDS for metallics, and specify the allowable, material data, and test conditions required from the Materials & Processes and Test teams.

• Automate and script analysis workflows – model generation, parametric studies, load case sweeps, and post-processing – using Python for Abaqus scripting, and develop closed-form and lower-order analysis methods in Python or MATLAB to size hardware quickly and to verify finite element results.

• Interface closely with the Mechanical Design, Materials & Processes, and Airborne Electronics teams to translate analysis results into design improvements and robust, certifiable hardware.

• Check and release design against the applicable stress and thermomechanical requirements, providing the stress sign-off for propulsion battery pack and PDU hardware releases.

• Define mod