hypersonica-prod - Hypersonica - 61 M&P Structures Engineer
Requirements
• A highly capable Mechanical Engineer with deep experience in materials, structures, or mechanical system design for extreme environments. • You bring strong expertise in at least one of the following, with working knowledge across the others: Advanced materials science (high‑temperature alloys, ceramics, composites) Stress and failure analysis (structural mechanics, fatigue, fracture, dynamics) Mechanical system engineering (vehicle‑level integration, dynamic modelling) • Comfortable tackling highly ambiguous, non‑linear engineering problems under tight performance and safety constraints. • Highly proficient with advanced simulation tools (e.g. OPTISTRUCT, NASTRAN, COMSOL) and modern CAD tools (e.g. Siemens NX). • Strong analytical capability, able to connect multi‑physics behaviour into actionable engineering decisions. • Experienced using test data to validate and challenge models, not treating simulation as an end in itself. • Detail‑driven yet able to think at the system and vehicle level, understanding how mechanical decisions affect overall performance. • Familiar with aerospace, defence, or other high‑performance engineering programmes where margins matter. • Technically curious, rigorous, and motivated by operating at the limits of materials and structural performance. • Driven by contributing to sovereign hypersonic capability, where correctness, robustness, and execution speed matter. • ## Security and Eligibility Requirement • Due to the nature of the work with the UK MOD, applicants must be a British Citizen (or Dual UK national with British citizenship) and eligible for UK Security Clearance (SC) and, where required, Developed Vetting (DV)
Responsibilities
• Own and solve thermo‑mechanical challenges for hypersonic missiles and aerospace vehicles operating in extreme flight environments. • Lead structural design and advanced analysis of critical vehicle components exposed to extreme aerodynamic loads, thermal gradients, and dynamic stresses. • Develop and maintain high‑fidelity simulation models (FEA and multi‑physics) to predict structural, thermal, and material behaviour under operational conditions. • Conduct detailed stress, fatigue, creep, fracture, and thermal stress analysis on novel composites, superalloys, ceramics, and refractory materials. • Define and shape mechanical system architectures, ensuring robust integration between propulsion systems, airframe structures, thermal protection, and control systems. • Investigate, select, and qualify high‑temperature materials and material systems capable of sustained operation above 1500°C. • Analyse material behaviour under thermal cycling, oxidation, ablation, and phase change, identifying risks and driving mitigation strategies. • Evaluate and influence manufacturing processes (additive manufacturing, advanced casting, welding, high‑precision fabrication) to ensure designs are buildable and scalable. • Identify material‑ and process‑driven failure modes, feeding insights back into design, analysis, and qualification plans. • Collaborate closely with propulsion, aerodynamics, and systems teams to translate requirements into manufatturable, testable mechanical designs. • Support and interpret experimental testing, using data to refine models, material selection, and system architectures. • Contribute across the full lifecycle from concept through simulation, prototype development, and design maturity.
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