Karan Vankani

Stress Engineer @Spirit AeroSystems

Richardson, TX, US

Support the Boeing Freighter program by conducting structural stress analysis (static, fatigue and damage tolerance analyses) on air-frame components (fuselage Section 41, wing box, engine, nacelles) using hand calculations, finite element methods (FEM) and industry standard tools (Boeing tools, PATRAN, CATIA)• Employ classical stress analysis methods to rapidly verify early design concepts, ensuring design feasibility before advanced simulation• Performed structural analysis for Nose wheel well/frames structures using Boeing tools for total of man hours• Developed the detail FEA analysis of large cargo door and small cutouts for composite skin and sub-structure using PATRAN and NASTRAN fora total of 150 man hours• Partner with design teams to iterate on splices, brackets, and stringer clips in CATIA V5, optimizing structural geometry for weight reduction and improved manufacturability• Prepared comprehensive Strength Check notes (SCNs) and substantiate design changes in line with FAA regulations, typically generating 400+pages per project• Analyze composite and metallic materials, bonded joints, bolted connections, and sandwich panels for various load cases.• Develop and review repair and rework instructions for structural discrepancies discovered during production or in-service.• Perform load path evaluation and interpret load envelopes from aerodynamic and flight load studies.• Generate and validate internal tools or scripts to improve workflow automation, post-processing, or reporting efficiency using Excel VBA, Python and MATLAB• Collaborate with quality and engineering teams to create audit reports and implement AS9100-compliant defect prevention and configuration plans throughout manufacturing processes

Dharmsinh Desai University

Bachelor of Technology - BTech, Mechanical Engineering

Embry-Riddle Aeronautical University

Master of Science - MS, Aerospace, Aeronautical and Astronautical Engineering