Trevor Haines
Senior Stress Analysis Engineer
Wichita, Kansas
Works on structural integrity and fatigue analysis for commercial aircraft components, with most projects centered around vibration issues, load-path validation, and recurring field failures that don’t show up cleanly in initial simulation models. Has spent years bridging the gap between FEA teams, manufacturing engineers, and test technicians to resolve problems that only appear under real operating conditions. Frequently pulled into late-stage investigations where timelines are tight and root causes are unclear.
Aerospace
Aerospace
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Professional Background
16 years
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Recently chased a high-cycle fatigue crack in a simple bracket. FEM predicted 30% margin, shaker replication said otherwise. Root cause: test article had realistic stack-up, paint, sealant, aged isolators, and torque scatter, which changed joint stiffness and damping. Our model used ideal bolts and uniform contact. Strain gauges lit up at a lug we barely meshed.Updating joint modeling (surface contact with micro slip, preload scatter, frequency-dependent damping) closed the gap. The life went fr...