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Shield AI

Posted 28 days ago

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Senior Staff Engineer, Aerostructures Design (R5072)

United StatesOn-siteFull-time

AI Summary

Senior Staff Structural Design Engineer responsible for the design, analysis, and validation of primary and secondary airframe structures for Shield AI’s autonomous aircraft, leading cross-disciplinary collaboration and ensuring producibility and mission readiness.

About this role

Founded in 2015, Shield AI is a venture-backed deep-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include the V-BAT and X-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With offices and facilities across the U.S., Europe, the Middle East, and the Asia-Pacific, Shield AI’s technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description:

Shield AI is seeking a Senior Staff Structural Design Engineer to play a critical role in the development of structural components for our next-generation autonomous aircraft. As a senior member of the Mechanical Engineering team, you will own the design and development of high-performance structural systems, from clean-sheet concepts to production-ready hardware.
You’ll work across disciplines to ensure structural integrity, manufacturability, and mission-readiness in one of the most advanced autonomous aircraft platforms being built today. This role is ideal for an experienced aerospace mechanical engineer who thrives in fast-paced, high-ownership environments and is passionate about building systems that matter.

What you'll do:

  • Lead the design and development of structural components and assemblies for Shield AI’s next-gen UAV platform, with a focus on primary and secondary aircraft structures.
  • Own the structural design lifecycle including concept generation, CAD modeling, detail design, and drawing release, ensuring high quality and traceability.
  • Use FEA tools to perform and guide linear and nonlinear structural analysis, stress analysis, and margin assessment under operational loads and edge cases.
  • Work closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to ensure seamless system integration across airframe and subsystem interfaces.
  • Support and lead efforts in material selection, focusing on composites, aluminum alloys, and advanced manufacturing approaches suited to mission and environment.
  • Participate in and lead design reviews, architecture discussions, and technical decision-making forums related to structural systems.
  • Oversee the design and execution of structural validation testing, including coupon-level, subcomponent, and full-system testing.
  • Guide the development of design documentation, analysis reports, interface definitions, and verification plans in compliance with MIL-STD, FAA, and internal Shield AI standards.
  • Mentor junior engineers and review team members’ work for technical rigor, performance, and manufacturability.
  • Collaborate with the manufacturing and flight test teams to transition designs from engineering to production and field deployment.
  • Identify opportunities to improve design processes, configuration management, and team workflows for increased engineering velocity and design quality.

    • Required qualifications:

  • Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
  • 10+ years of experience in aircraft structural design, with demonstrated ownership of components or systems in development, test, or production.
  • Deep understanding of composite and metallic structures, including material behavior, joints, and thermal/environmental effects.
  • Expertise in CAD tools (NX, CATIA, or SolidWorks) and FEA tools (ANSYS, Abaqus, NASTRAN, or similar).
  • Experience conducting or overseeing stress analysis, fatigue analysis, and design optimization.
  • Strong working knowledge of DFMA, GD&T, tolerance stackups, and structural layout principles.
  • Clear, concise technical communication skills and experience leading cross-functional engineering efforts.
  • A track record of technical excellence, high ownership, and a mission-driven mindset in challenging engineering environments.

    • Preferred qualifications:

  • M.S. degree in Aerospace or Mechanical Engineering.
  • Strong NX CAD skills
  • Experience supporting or leading Group 3–5 UAV, DoD aircraft, or high-performance aerospace vehicle programs.
  • Knowledge of aerospace standards (MIL-STD, ASME Y14.5, FAA FARS) and certification pathways.
  • Prior experience in flight vehicle integration, manufacturing liaison, or production support.
  • Familiarity with model-based engineering, digital twin development, or configuration management tools.
  • Demonstrated experience in failure analysis, design iteration, and test correlation.
  • Previous work in startup, R&D, or high-growth defense environments where agility and innovation are key.

    • Skills

    AbaqusAluminum AlloysAnsysASME Y14.5CAD ModelingCATIAComposite StructuresConfiguration ManagementDesign OptimizationDetailed DesignDFMADigital TwinFAA StandardsFatigue AnalysisFEAFlight Vehicle IntegrationGD&TMIL-STDModel Based EngineeringNASTRANNxSolidWorksStructural AnalysisTolerance Stackups

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