Mario Malnati

Team Leader - Aerospace Fatigue & Damage Tolerance

Zürich Metropolitan Area

About

Senior aerospace engineer with nearly 30 years of experience in fatigue and damage tolerance of aeronautical structures, covering both rotorcraft and fixed-wing aircraft. I have built my career at the intersection of advanced structural analysis, experimental validation and EASA certification, with formal responsibility as Compliance Verification Engineer (CVE) for Fatigue & Damage Tolerance on CS-23 and CS-27 programs. Currently, I am Team Leader for Fatigue & Damage Tolerance on the AW09 single-turbine helicopter at Kopter Group (Leonardo Helicopters), supporting the EASA CS-27 certification through definition of F&DT methodologies, fatigue loads and spectra, bench testing and authority interface. My technical focus includes: • Aerospace fatigue and damage tolerance (Safe Life, Flaw Tolerant Safe-Life, Fail Safe, Damage Tolerant, MLP / SLP) • Flaw tolerant Safe-Life of rotorcraft components in presence of small defects • Fatigue loads and spectra for fixed wing and rotorcraft • Fatigue testing from specimens to full-scale components • Fracture mechanics, crack growth and maintenance planning • FEM-based, multiaxial and vibration fatigue I combine deep technical expertise with team leadership and a pragmatic, certification-oriented mindset, developed across aerospace, automotive and advanced mobility programs in Switzerland, France, Germany and Italy. I am currently open to selective consulting and contractor opportunities in aerospace and advanced air mobility, particularly in international and certification-driven environments.

Experience

  • Team Leader Fatigue and Damage Tolerance at Kopter Group AG
    Jun 2015 - Present · 11 yrs 2 mos

    Responsible for Fatigue and Damage Tolerance of the CS-27 Single-Engine AW09 Helicopter.

  • Fatigue and Damage Tolerance Compliance Verification Engineer (CVE) at RUAG Aerospace Services GmbH
    Apr 2013 - May 2015 · 2 yrs 2 mos

    CVE for Fatigue and Damage Tolerance on Dornier 228 fleet, Dassault-Dornier Alpha Jet, Bell UH-1D.

  • Consultant Engineer – Structural Substantiation at Dassault Aviation
    Dec 2012 - Mar 2013 · 4 mos

    F&DT / stress analysis and validation on fuel tank surrounding structure of a business jet

  • Fatigue and Damage Tolerance Team Leader on the SK-105 Skylander Aircraft at GECI International
    May 2009 - Nov 2012 · 3 yrs 7 mos

    Team Leader for F&DT Activities on CS-23 Turboprop SK-105 SKYLANDER Aircraft

  • PSA - Peugeot Citroën - Senior Structural Engineer - Fatigue & Vehicle Dynamics at Groupe PSA
    Sep 2001 - Apr 2009 · 7 yrs 8 mos

    • Fatigue and structural analyses of body, chassis and suspension systems. Fatigue of welded joints. • Fatigue Testing Activities on Body-In-White and Suspensions Systems. • Development of coupled FEM–Multibody methodologies for vehicle endurance simulation. • NVH analyses and structural optimization of vehicle body and suspension architectures. • Industrialization of vehicle dynamics assessment methods. Coupled Multibody-FEM. • Crash analysis.