Principal Aerostructures Design Engineer (R5163)

InvestedintheMission; San Diego (CA); On-site; USD 240,000 - 360,000; Full time

Job summary

Shield AI seeks a Principal Aerostructures Design Engineer to own the design and development of high-performance structural systems for next-generation autonomous aircraft. You will drive concept through production-ready hardware, ensuring structural integrity, manufacturability, and mission readiness in a fast-paced environment.

You will mentor engineers, lead design reviews, perform advanced FEA, and collaborate across aerodynamics, propulsion, avionics, and manufacturing teams to ensure

Qualifications

• Bachelor’s or Master’s degree in Mechanical or Aerospace Engineering.
• 15+ years of experience in aircraft structural design, with ownership of components or systems.
• Deep understanding of composite and metallic structures, including behavior, joints, and environmental effects.
• Proficiency with CAD/FEA tools (NX/CATIA/SolidWorks; ANSYS/Abaqus/NASTRAN).
• Experience with stress, fatigue analysis and design optimization.
• Knowledge of DFMA, GD&T, tolerance stacks, and structural layouts.
• Strong technical communication and cross-functional leadership.
• Eligible for security clearance (S//SAR) if required.

Responsibilities

• Lead the design and development of primary and secondary aircraft structures.
• Own the structural design lifecycle from concept to release with traceability.
• Perform and guide linear/nonlinear structural analysis and margin assessment.
• Collaborate with aerodynamics, propulsion, avionics, and manufacturing teams.
• Lead material selection for composites and aluminum alloys; advanced manufacturing.
• Conduct design reviews and architectural discussions for structural systems.
• Oversee structural validation testing from coupons to full-scale tests.
• Develop design documentation, analysis reports, and verification plans per MIL-STD/FAA.
• Mentor junior engineers and review work for rigor and manufacturability.
• Partner with production and flight-test teams to transition designs to production.

Skills

Technical leadership

Cross-functional leadership

DFMA & GD&T

Fatigue analysis

Security clearance

Education

Bachelor’s or Master’s in Mechanical/Aerospace Engineering

Tools

NX CAD

CATIA

SolidWorks

ANSYS

Abaqus

NASTRAN

Job description

Shield AI is a venture-backed defense-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software, V-BAT and X-BAT aircraft, and Aechelon simulation and synthetic reality technologies. With offices and facilities across the U.S., Europe, the Middle East, and 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 Principal Aerostructures 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.
• 15+ 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.
• Ability to get a S//SAR level security clearance desired.

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.

#LI-JM2

#LF

Full-time regular employee offer package:

Pay within range listed + Bonus + Benefits + Equity

Temporary employee offer package:

Pay within range listed above + temporary benefits package (applicable after 60 days of employment)

Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location. All offers are contingent on a cleared background and possible reference check. Military fellows and part-time employees are not eligible for benefits. Please speak to your talent acquisition representative for more information.

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.

240000 - 360000 USD a year