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.

Key responsibilities include:

• Leading 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.

• Owning the structural design lifecycle including concept generation, CAD modeling, detail design, and drawing release, ensuring high quality and traceability.

• Using FEA tools to perform and guide linear and nonlinear structural analysis, stress analysis, and margin assessment under operational loads and edge cases.

• Working closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to ensure seamless system integration across airframe and subsystem interfaces.

• Supporting and leading efforts in material selection, focusing on composites, aluminum alloys, and advanced manufacturing approaches suited to mission and environment.

• Participating in and leading design reviews, architecture discussions, and technical decision-making forums related to structural systems.

• Overseeing the design and execution of structural validation testing, including coupon-level, subcomponent, and full-system testing.

• Guiding the development of design documentation, analysis reports, interface definitions, and verification plans in compliance with MIL-STD, FAA, and internal Shield AI standards.

• Mentoring junior engineers and reviewing team members' work for technical rigor, performance, and manufacturability.

• Collaborating with the manufacturing and flight test teams to transition designs from engineering to production and field deployment.

• Identifying opportunities to improve design processes, configuration management, and team workflows for increased engineering velocity and design quality.

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.

Required qualifications include:

• 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 include:

• 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.

Salary: $166,632 - $249,948 a year

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