Hill Helicopters
Hill Helicopters
Hill Helicopters
Hill Helicopters

Aircraft Stress Engineer

Job No: HLH28
Location: Stafford

About the Role:

Join a dynamic UK-based helicopter OEM as an Aircraft Stress Engineer supporting the structural integrity and certification of a new generation of civil rotorcraft. This is an exciting opportunity to work on a clean-sheet light helicopter programme, applying both classical hand calculations and advanced finite element analysis (FEA) to ensure airworthiness and optimal structural performance.

The successful candidate will collaborate closely with design, testing, and certification teams, using ANSYS alongside traditional engineering methods to perform stress, strain, fatigue, and damage tolerance analyses. This role demands a solid foundation in aerospace structural principles, hands-on FEA experience, and an analytical mindset capable of translating complex loads into robust, efficient designs.

Key Responsibilities:

  • Perform detailed structural stress analysis using hand calculations, classical methods, and FEA tools (primarily ANSYS) to validate mechanical components and assemblies.
  • Develop and maintain finite element models of rotorcraft airframe and mechanical systems.
  • Assess loads, stresses, strains, and fatigue life of aircraft structures in compliance with relevant certification standards.
  • Support design engineers by providing guidance on structural integrity, load paths, and design improvements.
  • Liaise with test teams to correlate analysis results with physical test data and support failure investigations.
  • Prepare technical reports, stress analysis documentation, and certification substantiation packages.
  • Contribute to the development and continuous improvement of stress analysis methodologies and tools.
  • Work collaboratively within a multidisciplinary engineering team in a fast-paced, innovative environment.

Requirements:

Essential:

  • Degree in Aerospace Engineering, Mechanical Engineering, or a related discipline with a focus on structures.
  • Proven experience performing hand calculations for structural stress and load analysis.
  • Hands-on experience with ANSYS for finite element modelling and analysis.
  • Strong understanding of rotorcraft or fixed-wing aircraft structural principles and certification requirements (e.g., CS-27 or FAR Part 27).
  • Competency in fatigue and damage tolerance assessment.
  • Ability to interpret complex load cases and translate into robust structural designs.
  • Effective communication skills with the ability to produce clear, comprehensive analysis reports.
  • Self-motivated, detail-oriented, and a proactive team player.

Desirable:

  • Previous experience in rotorcraft or light aircraft structural stress analysis.
  • Familiarity with composite material stress analysis.
  • Exposure to PLM systems and data management tools.
  • Knowledge of structural test planning and test correlation.

What We Offer:

  • The chance to be a key contributor to a credible new light helicopter programme within a leading UK rotorcraft OEM.
  • Exposure to a broad range of structural engineering challenges in a fast-moving development environment.
  • A collaborative, close-knit team culture focused on innovation and excellence.
  • Access to state-of-the-art FEA tools, on-site test facilities, and professional development support.
  • Competitive salary and comprehensive benefits.
Apply Now

Privacy Acknowledgment

Recruitment Privacy Notice

Hill Helicopters is committed to protecting the privacy and security of your personal information.   This privacy notice describes how we collect and use personal information about you during the recruitment process.

What information do we collect?

In connection with your application for work with us, we will collect, store, and use the following categories of personal information about you:

  • The information you have provided to us with your application including your cv or resume
  • Any information you provide to us during an interview
  • Information you provide in relation to your right to work documentation

We may also collect, store and use the following “special categories” of more sensitive personal information:

  • Information about your criminal record
  • Information about your health and any medical condition

We collect this personal information variously from you, the candidate, our employer background checks, your named referees and information from publicly available sources such as the Internet. 

How will we use your personal data?

We will use the personal data that you have provided to assess whether you are suitable for the position for which you have applied.   We also need your personal data to communicate and to enter into an employment agreement with you if you are successful.

We will review your health information if we need to make adjustments to accommodate your condition, either in the recruitment process or in your employment if your application is successful.

We may carry out a criminal records check in order to satisfy ourselves that you have not been convicted of any offence that makes you unsuitable for the role.  We use a third party to conduct this search. 

Who has access to data?

Your information will be shared internally among our senior management team, members of the HR team and other interviewers involved in the recruitment process.

We will not share your data with third parties, unless your application for employment is successful. We may then share your personal data with the referees that you have provided to us and the third party that we use to carry out background and criminal record checks. Those third party providers are required to take appropriate security measures to protect your personal information in line with our policies.

How do we protect data?

We take the security of your data seriously. We have put in place appropriate and adequate technical and physical measures to prevent your personal information from being used or accessed without authority. We limit access to your personal information to those employees and agents who have a legitimate business need to know. We have put in place procedures to deal with any suspected data security breach. We will notify you of any suspected breach where we are legally required to do so.

For how long do we keep data?

If your application for employment is unsuccessful, we will hold your data on file for twelve months after the end of the recruitment process. After this period, we will securely destroy your personal information.

If your application for employment is successful, personal data gathered during the recruitment process will be transferred to your personnel file and be kept for the period of your employment and thereafter consistent with our privacy policy.  

Your rights

You can at any time:

  • access and obtain a copy of any of your personal data that we hold;
  • ask us to amend incorrect or incomplete data;

If you would like to exercise any of these rights, please contact a member of the HR team.


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About Us

We are building a revolutionary, private light helicopter and engine at our design and production centre in Stafford. The Hill HX50 satisfies a long-unfulfilled demand in the aviation market for a modern, stylish and affordable rotary aircraft. Its composite design, interior luxury and advanced powerplant makes supercar styling, performance and comfort available to helicopter buyers for the first time. The aircraft and engine are all British designed and built in Hill’s own factory. By eliminating expensive supply chains, Hill is dramatically reducing the cost of helicopter ownership and operation. The biofuel-ready engine and cellulose biowaste fuel solution introduce a commercially and technically achievable path to net-zero in general aviation. Reflecting the gap in the market that it fills, the response to the Hill helicopter has exceeded all expectations. HX50 has become the world’s fastest selling helicopter -- redefining the general aviation market globally.