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.

Archer is committed to working with and providing reasonable accommodations to job applicants with physical or mental disabilities, and those with sincerely held religious beliefs. Applicants who may require reasonable accommodation for any part of the application or hiring process should provide their name and contact information to Archer’s People Team at people@archer.com. Reasonable accommodations will be determined on a case-by-case basis.