Senior Fatigue & Damage Tolerance Analysis Engineer in Bicester

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 Senior Fatigue & Damage Tolerance Analysis Engineer to join the team to ensure lead the development and deployment of fatigue and damage tolerance (F&DT) analysis methods for metallic and composite structures, both rotating and static components, for electric propulsion architecture including the motor.

Key responsibilities will include:

• Carry out detailed fatigue and crack growth analysis using both first‑principles and industry recognised analysis/calculation methods.
• Analyse the life of rotating metallic (aluminium, steel and titanium) components consistent with Group A critical parts.
• Assess results against customer specifications and draw sound conclusions, including the generation of LCF, Damage Tolerance and Residual Fatigue.
• Determination of fatigue allowable stress levels for sizing.
• Determination of inspection intervals for structural parts consistent with CS25 requirements.
• Collaborate closely with Design, Test and Airworthiness teams to integrate F&DT solutions into the certification programmes.
• Author technical documentation to support regulatory submissions.
• Develop ideas and design solutions to practical challenges arising from new product design.
• Drive and manage test work that will validate the analysis.
• 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 experience in evaluation of static and rotating components, specifically CS25 level lifing compliance with respect to LCF, Damage Tolerance and Residual Fatigue.
• Proven experience of Critical Parts lifing for LCF, Damage Tolerance and Residual Fatigue (Deterministic and Probabilistic).
• Calculation of equivalent (Seq) stresses (fatigue and crack propagation), understanding of mission profiles, rainflow counting, Miner's rule and F&DT databases.
• Analysis of metallic and composite structures (Plain Strength checks, Buckling, Bolted joint analysis).
• Knowledge of static and fatigue design values (Ftu, Fty, Fcy, AFI parameters, S-N curve parameters, fracture toughness, etc).
• Possess a strong foundation in the area of load/stress analysis with abilities to formulate "free body diagrams" and identify load path of structures.
• Practical knowledge of electric machines or rotating assemblies.
• Strong experience with FEA methods and programs e.g. ANSYS (ideally).
• Self-sufficient and able to work with minimal managerial input.
• Good understanding of aerospace materials and associated mechanical properties and processing.
• Confident with customers and suppliers, able to interpret requirements and understand issues.
• 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.

Desirable:

• Experience in aerospace certification programmes.
• Experience with polymers-creep evaluation.

Are you Evolito? Apply now for immediate consideration.