Senior Staff Aerostructures Design Engineer (RX) (R5846)

The role

You will lead the design, analysis and release of structural components for Shield AI's next-generation UAV platform. You will also guide structural validation testing and help move designs into production and field deployment.

What you will do

• Lead design and development of primary and secondary aircraft structures for the next-gen UAV platform.
• Own the structural design lifecycle: concept, CAD modeling, detail design and drawing release.
• Perform and guide linear and nonlinear structural, stress and margin analysis using FEA tools.
• Work with aerodynamics, propulsion, avionics, payload and manufacturing teams on system integration.
• Support and lead material selection, including composites, aluminum alloys and advanced manufacturing.
• Lead design reviews and structural technical decision-making.
• Oversee structural validation testing at coupon, subcomponent and full-system levels.
• Guide design documentation, analysis reports, interface definitions and verification plans to MIL-STD, FAA and internal standards.
• Mentor junior engineers and review their work for rigor, performance and manufacturability.
• Work with manufacturing and flight test teams to move designs into production and field deployment.

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 ownership of components or systems in development, test or production.
• Deep understanding of composite and metallic structures, including 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 and experience leading cross-functional engineering efforts.
• A track record of technical excellence, high ownership and a mission-driven mindset.
• Ability to obtain an S//SAR level security clearance (listed as desired).

Nice to have

• 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.

Benefits

• Full-time regular employees receive bonus, benefits and equity in addition to pay.
• Temporary employees receive a temporary benefits package, applicable after 60 days of employment.
• Military fellows and part-time employees are not eligible for benefits.

Before you apply

• All offers are contingent on a cleared background and possible reference check.
• Pay depends on factors including skill set, experience, licenses and certifications, and work location.
• Please speak to your talent acquisition representative for more information about offers.

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.