Staff Aerostructures Design Engineer (R5159)

The role

You will design structural components for a next-generation autonomous aircraft, from concept through production release. You will work with aerodynamics, propulsion, avionics, payload and manufacturing teams to support system integration.

What you will do

• Design and develop structural components and assemblies for the next-generation UAV platform, primary and secondary structures.
• Execute the design lifecycle: conceptual development, initial CAD modeling, detailed design and drawing release.
• Perform hand calculations for stress or strain and limited basic FEA, with guidance from senior engineers.
• Collaborate with aerodynamics, propulsion, avionics, payload and manufacturing teams on airframe integration.
• Support structural validation, including coupon testing, subcomponent testing and system-level verification.
• Generate design documentation, drawings, interface definitions and analysis reports to aerospace standards.
• Partner with manufacturing and flight test teams to resolve build issues and support hardware through test and deployment.
• Take part in design reviews and technical discussions, presenting work and incorporating feedback.
• Build technical depth in structural layout, joints, fasteners, tolerancing and structural optimization.

Required qualifications

• Bachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering or a related discipline.
• 8+ years of experience in aircraft structural design or closely related aerospace structures.
• Experience designing and releasing structural components in development or production environments.
• Working knowledge of composite and metallic structures, including fasteners, bonded joints and load paths.
• Proficiency in CAD tools such as NX, CATIA, SolidWorks or similar.
• Understanding of GD&T, tolerance stackups and DFMA principles.
• Strong written and verbal technical communication skills.
• Demonstrated ability to operate in fast-paced, high-ownership engineering environments.
• Ability to obtain an S//SAR level security clearance.

Nice to have

• M.S. degree in Aerospace or Mechanical Engineering.
• Experience supporting UAV, DoD or aerospace vehicle programs.
• Familiarity with aerospace standards such as MIL-STD, ASME Y14.5 and FAA.
• Experience supporting hardware through test, failure analysis and design iteration.
• Exposure to composite design and manufacturing methods.
• Experience using FEA tools such as ANSYS, Abaqus, NASTRAN or similar for linear structural analysis.

Benefits

• Bonus for full-time regular employees.
• Benefits for full-time regular employees.
• Equity for full-time regular employees.
• Temporary benefits package for temporary employees, applicable after 60 days of employment.

Before you apply

• An S//SAR level security clearance is desired.
• All offers are contingent on a cleared background and possible reference check.
• Military fellows and part-time employees are not eligible for benefits.

About the company

Shield AI is a venture-backed defense-tech company that builds intelligent systems to protect service members and civilians. Its products include Hivemind autonomy software, V-BAT and X-BAT aircraft, and Aechelon simulation technologies.