Stress Engineer - Propulsion

Help Build Europe's Hypersonic Capability
 
At Hypersonica, we’re redefining what’s possible in European defence technology. We exist to deliver speed, resilience, and technological independence at a pace that sets a new standard. We are a small, elite team working on problems that matter, and solving them fast.
 
By joining Hypersonica, you’re not stepping into a predefined role. You’re joining a talent dense environment where every individual shapes the direction of the company. Our philosophy is to hire a small number of exceptional people with broad, deep technical capability, strong judgement, and the ability to operate autonomously.
 
We hire for talent, not rigid boxes. This role represents a business need, but the way it evolves will be shaped by the individual. If you’ve achieved what others said was impossible, or you bring a unique combination of skills that doesn’t fit a traditional mould, we want to hear from you. The work you do here directly contributes to Europe’s technological independence.

What you'll do

- Own stress analysis and structural integrity for booster hardware, from early concept sizing through to qualified, flight-ready designs.

- Analyse booster structures and components under extreme thermal, pressure, vibrational, and mechanical loads, using hand calculations and finite element (FE) methods.

- Define and manage booster load cases across the full life cycle, including manufacture, handling, transport, storage, test, and flight.

- Carry out structural safety assessments for hardware containing energetic materials, including failure mode assessment, safety factors and margins, and the effects of structural failure.

- Produce the structural evidence for booster safety cases and hazard analyses, working closely with the Propulsion Systems Engineer and the HSE (Health, Safety and Environment) and Quality teams.

- Assess the structural effects of manufacturing defects, non-conformances, and design changes, and give clear, timely disposition advice.

- Define the structural requirements for proof, acceptance, and qualification tests, and correlate test results with analysis.

- Work closely with design, propulsion, thermal, and systems engineers, to make sure designs are safe, analysable, and lightweight.

- Take part in design and safety reviews, and present analysis results and margins clearly to engineering leadership and customers.

- Write clear, traceable stress reports and safety assessment documentation under configuration control.

Who you are

- A hands-on Stress Engineer with experience analysing high-load flight hardware, pressure vessels, or rocket and booster structures.

- Degree in Mechanical or Aerospace Engineering (or related discipline); a postgraduate qualification in structural mechanics or a related field is a plus.

- Strong grounding in structural mechanics, including strength, stability, fatigue, fracture, and thermal stress, with confidence in both hand calculations and FE analysis.

- Experience with FE tools (e.g. Abaqus, MSC Nastran, Ansys) and turning results into practical design and safety decisions.

- Experience producing structural safety assessments or safety case evidence in a regulated or safety-critical industry such as aerospace, defence, nuclear, or pressure systems.

- Experience with energetic or pressurised systems, and the safety requirements that apply to them, is a strong advantage.

- Programming skills (e.g. Python or MATLAB) for automation, post-processing, and test correlation are an advantage.

- Comfortable making sound engineering judgements with incomplete data in fast‑moving, prototype‑heavy environments, without compromising on safety.

- Fluent English is essential; German is an advantage.

What we offer

- A mission driven environment with the opportunity to work on one of Europe’s most consequential defence challenges, with direct impact on sovereign capability and security.

- Daily collaboration with top experts across engineering, operations, and defence, with real opportunity to learn from the best, contribute, and grow.

- High ownership and autonomy; no time tracking, no micromanagement, just clear objectives and accountability for outcomes.

- A fast paced environment where good ideas are implemented quickly, and feedback from test and flight drives real decisions.

- A culture that values clarity, integrity, and excellence, and supports people who take initiative and push boundaries responsibly.

- Competitive compensation and real share options aligned to responsibility and impact, not tenure or hierarchy.

At Hypersonica, every hire raises the bar. We are deliberately small, intensely capable, and deeply mission-driven. If this role feels like a strong fit, or if you believe you bring something exceptional that goes beyond the description, we encourage you to apply.
 
Hypersonica is an equal-opportunity employer and assesses candidates solely on merit, capability, and potential.
 
You can apply directly to this role or reach out to Nathan Sweeney, Head of Talent. We review every application and aim to respond to all candidates within two weeks, whether the answer is yes or no.