Senior Stress Engineer - Energy Storage Unit (m/f/d)

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Company Description

We at Volocopter are the pioneers of electric air taxis, i.e. aircraft that take off and land vertically (eVTOLs). We bring urban air mobility to life, by getting air taxis and drones off the gorund in a way that complements current transportation options in megacities across the globe. Our aim is to offer affordable on-demand air taxi services that fly people to their destination quickly and safely. In 2011 we performed the first-ever piloted flight of a purely electric multicopter and have since showcased numerous public flights with our full-scale VoloCity aircrafts (

Job Description

As the Senior Stress Engineer, your mission is to ensure the mechanical design of the Energy Storage Unit (ESU) complies with requirements and pass the certification process. You will provide technical expertise to ensure that we achieve our company goals for a successful design of our Energy Storage Unit.

Additionally, you apply FEA simulation and define testing requirements for full-scale structural tests. Within a highly motivated, multi-disciplinary team you develop and refine the state-of-the-art ESU structure of the Volocopter that is key to its best-in-class performance.

Your mission during this flight:

  • Detailed sizing, static, dynamic, damage tolerance, and modal analysis of structural components utilizing both classical hand calculations and finite element analysis
  • Verify structural integrity by performing analysis using analytical methods, finite element models/simulations, and other analysis tools throughout the product life-cycle to develop the structural environment, characteristics, and performance
  • Develop ESU structural models for stress analysis and sizing for trade studies and manufacturing optimization
  • Evaluate the mechanical strains and stresses due to Mechanical, Electrical and Thermal loads
  • Perform fatigue and lifetime as well as crashworthiness evaluations
  • Composite ply stack optimization for weight reduction while maintaining manufacturing constraints
  • Assist in design reviews and signing off on structural parts
  • Review and Approve Stress Reports
  • Define and document structural load cases, certification test plans, and test results to substantiate for regulatory agencies that requirements are satisfied
  • Accountable for reviews of design, ESU structural configuration layouts, and detail design including structural layouts, preliminary sizing, joint layouts, and part design, utilizing metallic, plastic and composite materials
  • Conducting design trades, optimizations for final product configuration definitions considering safety, strength, weight, & producibility


Check in your professional skills

Required Skills:

  • Mechanical or Aerospace Engineering Degree (MSc, Ph.D.)
  • Minimum 7 years of professional experience as a stress engineer performing structural analysis and FEM of composite, plastic and metal structure
  • Experience in working with aerospace standards as CS23/CS27/SC-VTOL/DO-160G/DO-311A
  • Advanced proficiency in finite element analysis, including nonlinear static and dynamic analysis of composite, plastic or metallic structures
  • In-depth knowledge of loading scenarios, free body diagrams, and structural behavior of aircraft components
  • Ability to generate and review detailed analysis reports and aircraft type certification documents
  • Experience in the design and implementation of composite, plastic and metallic structures as solutions to complex engineering requirements
  • Experience in structural testing, testing standards, test planning, and test correlation
  • Track record of successfully performing light-weight design projects
  • Proficiency with CAD
  • Experience in aerospace industry

Preferred skills:

  • Experience with / in:
    • battery design/development activities for material selection
    • thermal runaway cases
    • manufacturing processes for battery pack structural/functional components
  • Desire to work in a fast-paced work environment with a motivated team
  • Dedicated to time-based activities & deadlines
  • Team player with a positive attitude and excellent problem-solving skills
  • Knowledge of business agility and ability to work within scaling frameworks (e.g. SAFe)

Additional Information

Work mode: 5 Days Onsite

Some of our Volocopter flight perks:

  • A fast-growing high-tech company with a broad network of top investors and partners
  • The chance to help shape the future of aviation
  • The chance to create new things from scratch & manage your own projects
  • Personal accountability, and growth & learning opportunities, based on your skills
  • An inspiring workplace with modern workstations, flexible hours, efficient communication, flat hierarchies & fantastic team spirit
  • An attractive salary package

Our differences are what makes us great. Here at Volocopter, we value equal opportunities and trust, and we give each and every one of our employees the chance to voice their opinions. As air mobility industry innovators, we believe that changing the world starts on the team level. We are fully committed to driving this innovation by celebrating diversity and fostering an inclusive culture where everyone is treated equally and respectfully, regardless of our different backgrounds and job titles.