Senior Flight Test Data Engineer, Loads

What You'll Do

• As a Senior Flight Test Loads Data Engineer, you'll sit at the intersection of aircraft loads analysis and flight test operations — designing and operating the systems that capture, process, and validate loads data from our aircraft, and turning that data into actionable structural insights that drive certification and design decisions.
• Design, configure, and maintain flight test data acquisition system (DAS) software for structural loads measurements, including strain gauges, accelerometers, pressure transducers, and inertial sensors
• Develop and validate loads equations and transfer functions to derive internal structural loads from measured flight data
• Plan and execute loads survey flight test programs in coordination with flight test engineers and structural analysts
• Process, reduce, and quality-check large flight test datasets; identify anomalies and ensure data integrity across test campaigns
• Build and maintain automated data pipelines and analysis tools to accelerate loads extraction, fatigue spectrum development, and design loads validation
• Develop fatigue and loads spectra for powertrain and airframe components using flight-measured data
• Compare flight test loads data against analytical models; drive model updates and structural dispositions
• Support stress and damage tolerance analysis of primary and secondary structure using test-derived loads
• Compile test reports and loads documentation to support engineering drawing releases and FAA certification deliverables
• Provide technical guidance on instrumentation strategy, sensor selection, and data quality trade-offs across programs

What You Need

• 5+ years of experience in flight test loads, structural test, or loads and dynamics engineering on aircraft, spacecraft, or advanced air mobility platforms
• Bachelor's degree in Aerospace, Mechanical, Electrical, or related Engineering field (M.S. preferred)
• Hands-on experience with flight test data acquisition systems — hardware configuration, sensor integration, signal conditioning, and telemetry
• Proficiency developing loads equations and deriving structural loads from flight measurements (strain-gauge bridges, shear panels, accelerometers)
• Strong scripting and data analysis skills in Python and/or MATLAB, including automated data processing pipelines and visualization
• Experience with loads and fatigue spectrum development from measured flight data
• Working knowledge of structural analysis methods — classical hand calculations and/or FEA — sufficient to interpret and validate loads results
• Familiarity with fatigue and damage tolerance concepts (spectra development, AFGROW/NASGRO, NDE methods)
• Ability to manage multiple test campaigns simultaneously and communicate technical results clearly across disciplines

Bonus Qualifications

• Experience with FAA certification under Part 23 or Part 27, including loads substantiation documentation
• Experience with RCAS, CAMRADII or similar rotorcraft comprehensive analysis.
• Proficiency with FEA codes such as Nastran, Optistruct, Ansys, or Abaqus
• Familiarity with classical aerospace sizing references (Bruhn, Niu, Roark)
• Background in signal processing, filtering, or time-frequency analysis of structural response data
• Experience with database tools or cloud data infrastructure for large-scale test data management

At Archer we aim to attract, retain, and motivate talent that possess the skills and leadership necessary to grow our business. We drive a pay-for-performance culture and reward performance that supports the Company’s business strategy. For this position we are targeting a base pay between $144,000 - $180,000. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.