Principal Stress Engineer at Expleo in Preston, England, GB

Overview

Expleo is a trusted partner for engineering, quality services, and digital transformation. We collaborate with world-leading aerospace manufacturers, delivering cutting-edge solutions in structural analysis, finite element modelling, numerical simulation, and certification support. At Expleo, we foster innovation, technical excellence, and professional growth, empowering our teams to shape the future of aerospace engineering.

We are looking for a technically skilled and motivated Principal Engineer to manage a team of engineers (up to 15) focused on stress and technical analysis of advanced composite and metallic structure. This role requires strong expertise in composite and metallic materials – ideally next-generation technologies – and the ability to lead technical decision-making, stakeholder engagement, and methodology development.

This role is primarily based in the Military Air domain, working with a major OEM.

Responsibilities

• Lead an engineering team to deliver stress analysis work packages and documentation.
• Manage project schedules, cost estimates, and team resources to meet objectives.
• Make key technical decisions on design architecture, material performance, and structural integrity.
• Conduct detailed stress analysis on structures, including:
  • Strength, stiffness, buckling, and joint assessments
  • Sandwich and thermoset composite panel evaluations
  • Damage tolerance analysis (e.g., open hole, compression-after-impact)
• Perform finite element analysis using recognized toolsets (e.g., Nastran/Patran, Simcenter 3D, Hyperworks)
• Generate stress documentation including reserve factor summaries, justifications, and certification reports.
• Identify and mitigate technical risks within assigned projects.
• Support test planning and alternative compliance strategies (e.g., analysis, similarity)
• Interpret design data for stress analysis, including materials, dimensions, tolerances, and manufacturing processes.
• Deliver project outputs to quality standards and deadlines.
• Collaborate with local and remote teams.
• Participate in technical and customer reviews, including formal gate reviews.
• Provide technical guidance and mentorship to team members.
• Hold or be capable of obtaining stress signatory authority.

Qualifications

• Degree in Aerospace Engineering, Mechanical Engineering, or a related discipline.
• Demonstrated leadership in technical project delivery.

Essential skills

• Strong understanding of composite and metallic materials and structures.
• Proficiency in stress analysis techniques for aerospace components.
• Skilled in finite element modelling and post-processing.
• Ability to interpret complex design data and translate into stress assessments.
• Effective communication and stakeholder engagement.
• Strong documentation and reporting skills.
• Previous signatory authority for stress reports and drawings.
• Knowledge of military fast jets.
• Familiarity with wingbox design and load interface structures.
• Knowledge of certification processes and compliance strategies.

Experience

• Significant experience in aerospace stress analysis, particularly with composite and metallic structures.
• Hands-on experience with FEA tools such as Nastran/Patran/Apex and Simcenter 3D.
• Track record of delivering technical work packages within time and budget constraints.
• Experience working in multi-disciplinary and geographically distributed teams.
• Experience on fast jets.
• Experience with next-generation composite and metallic materials and technologies.
• Experience in guiding junior engineers and managing small teams.
• Proven experience in composite structural analysis and design.

Benefits

• Collaborative working environment – we stand shoulder to shoulder with our clients and our peers through good times and challenges

• We empower all passionate technology loving professionals by allowing them to expand their skills and take part in inspiring projects

• Expleo Academy - enables you to acquire and develop the right skills by delivering a suite of accredited training courses

• Competitive company benefits

• Always working as one team, our people are not afraid to think big and challenge the status quo

• As a Disability Confident Committed Employer we have committed to:

  • Ensure our recruitment process is inclusive and accessible
  • Communicating and promoting vacancies
  • Offering an interview to disabled people who meet the minimum criteria for the job
  • Anticipating and providing reasonable adjustments as required
  • Supporting any existing employee who acquires a disability or long term health condition, enabling them to stay in work at least one activity that will make a difference for disabled people

“We are an equal opportunities employer and welcome applications from all suitably qualified persons regardless of their race, sex, disability, religion/belief, sexual orientation or age”.

We treat everyone fairly and equitably across the organisation, including providing any additional support and adjustments needed for everyone to thrive