Shield AI is seeking a Senior Staff Aerostructures Design Engineer to play a critical role in the development of structural components for our next-generation autonomous aircraft.
\nAs 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.
\nKey responsibilities include:
\nLeading 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.
\nOwning the structural design lifecycle including concept generation, CAD modeling, detail design, and drawing release, ensuring high quality and traceability.
\nUsing FEA tools to perform and guide linear and nonlinear structural analysis, stress analysis, and margin assessment under operational loads and edge cases.
\nWorking closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to ensure seamless system integration across airframe and subsystem interfaces.
\nSupporting and leading efforts in material selection, focusing on composites, aluminum alloys, and advanced manufacturing approaches suited to mission and environment.
\nParticipating in and leading design reviews, architecture discussions, and technical decision-making forums related to structural systems.
\nOverseeing the design and execution of structural validation testing, including coupon-level, subcomponent, and full-system testing.
\nGuiding the development of design documentation, analysis reports, interface definitions, and verification plans in compliance with MIL-STD, FAA, and internal Shield AI standards.
\nMentoring junior engineers and reviewing team members' work for technical rigor, performance, and manufacturability.
\nCollaborating with the manufacturing and flight test teams to transition designs from engineering to production and field deployment.
\nIdentifying opportunities to improve design processes, configuration management, and team workflows for increased engineering velocity and design quality.
\nThis 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.
\nRequired qualifications include:
\nBachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
\n10+ years of experience in aircraft structural design, with demonstrated ownership of components or systems in development, test, or production.
\nDeep understanding of composite and metallic structures, including material behavior, joints, and thermal/environmental effects.
\nExpertise in CAD tools (NX, CATIA, or SolidWorks) and FEA tools (ANSYS, Abaqus, NASTRAN, or similar).
\nExperience conducting or overseeing stress analysis, fatigue analysis, and design optimization.
\nStrong working knowledge of DFMA, GD&T, tolerance stackups, and structural layout principles.
\nClear, concise technical communication skills and experience leading cross-functional engineering efforts.
\nA track record of technical excellence, high ownership, and a mission-driven mindset in challenging engineering environments.
\nPreferred qualifications include:
\nM.S. degree in Aerospace or Mechanical Engineering.
\nStrong NX CAD skills.
\nExperience supporting or leading Group 3–5 UAV, DoD aircraft, or high-performance aerospace vehicle programs.
\nKnowledge of aerospace standards (MIL-STD, ASME Y14.5, FAA FARS) and certification pathways.
\nPrior experience in flight vehicle integration, manufacturing liaison, or production support.
\nFamiliarity with model-based engineering, digital twin development, or configuration management tools.
\nDemonstrated experience in failure analysis, design iteration, and test correlation.
\nPrevious work in startup, R&D, or high-growth defense environments where agility and innovation are key.
\nSalary: $166,632 - $249,948 a year
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