Stress Engineer in Banbury

Evolito’s mission is to accelerate the adoption of electric propulsion in aerospace applications in support of a net-zero world. We will help to revolutionise personal mobility and transform our towns and cities with clean, noise-free air transportation. Evolito develops and manufactures class-leading, lightweight, high-power, and high-torque-density electric propulsion systems for a range of aerospace markets, including EVTOL, Unmanned Aerial Vehicles and General Aviation. As well as ultra-high performance, low-weight electric motors and controllers, Evolito specialises in high integrity, bespoke battery systems for the aerospace and defence markets. The team is scaling rapidly and has ambitious growth plans over the next twelve to eighteen months.

As part of our current high‑growth phase, we are seeking a Stress Engineer to join us to develop robust designs for electric propulsion architecture including the motor, controller, gearbox and heat exchanger. In addition, you will be responsible for designing and developing new concepts to optimise the electric propulsion unit performance and durability that are suitable for manufacture, as well as supporting physical testing required to verify CAE analyses and provide data to support conclusions.

Key responsibilities will include:

• Undertake Finite Element Analysis (FEA) for structural and vibration (modal and forced response) analyses on electric propulsion unit (EPU) assemblies and sub-assemblies.
• Validate and assess results against customer specifications and draw sound conclusions.
• Carry out a fatigue evaluation based on FEA results.
• Use FEA optimisation tools to derive solutions based on strength, weight reduction and manufacturability.
• Develop ideas and design solutions to practical challenges arising from new product design.
• Propose material and process selections suitable for loading conditions and mass volume production.
• Undertake and draw conclusions on root cause analysis of products and processes.
• Liaise with key suppliers and customers on design and development issues, resolve to the optimal solution and understand the compromises.
• Support DFMEAs, other quality techniques and complete actions required to mitigate risks.
• Write specifications and reports as required through the product lifecycle, utilising a structured approach to problem‑solving techniques.

Skills and experience required:

• Proven previous experience as a Stress Engineer (or similar) in a design and development environment.
• Practical knowledge in the design, use, and application of electric machines or rotational/complex components.
• A strong mechanical or electrical engineering background, but more importantly, the ability to apply knowledge to real‑world situations.
• Strong experience with finite element analysis methods and programs e.g. ANSYS, Abaqus, etc.
• Good understanding of aerospace materials and associated mechanical properties and processing.
• Confident with customers and suppliers; ability to interpret requirements and understand issues.
• Creative problem solver with an analytical approach to implementation.
• Ability to work under own initiative.
• A flexible approach to work with the desire to thrive in a dynamic, fast‑moving environment.
• Strong communication skills (both written and verbal), good collaboration skills, and the ability to work effectively across teams.
• Self‑motivated with the determination to succeed.
• Willingness to travel as required.
• Experience with rotor dynamics and vibration (forced response) analyses.
• Composite materials evaluation techniques, both simulation and physical.