Senior Aerostructures Design Engineer (R5158)

Shield; Dallas (TX); On-site; USD 130,000 - 200,000; Full time

Benefits offered by this job

Bonus

Equity

Benefits

Job summary

Shield AI is seeking a hands-on Structural Engineer to design and release primary and secondary airframe structures for its next-generation UAV platform. You will work with aerodynamics, propulsion, avionics, payload, and manufacturing teams, performing CAD modeling, hand calculations, and design reviews to ensure robust, lightweight structures.

You will develop documentation, interface definitions, and analysis reports while continuously improving structural layout, fasteners, tolerancing, and

Qualifications

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

Responsibilities

• Design and develop structural components and assemblies for UAV platform.
• Conduct full design lifecycle from conception to drawing release.
• Perform hand calculations for stress/strain with guidance from seniors.
• Collaborate with aerodynamics, propulsion, avionics, payload, and manufacturing teams.
• Support structural validation including coupon and system-level testing.
• Generate design documentation, drawings, interfaces, and analyses.
• Partner with manufacturing and flight test teams to resolve issues.
• Participate in design reviews and present work clearly.
• Improve structural layout, joints, tolerancing, and optimization.

Skills

Aircraft structural design

Fast-paced eng env

Technical communication

S//SAR clearance eligible

Education

B.S. in Mechanical Eng

M.S. in Aerospace Eng

Tools

NX

CATIA

SolidWorks

ANSYS/FEA

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-BATaircraft, 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.

What you'll do:

• Design and develop structural components and assemblies for Shield AI’s next-generation UAV platform, supporting both primary and secondary aircraft structures.
• Execute all stages of the design lifecycle including conceptual development, initial CAD modeling, detailed design, and drawing release.
• Perform hand calculations for stress or strain with limited basic FEA analysis, with guidance from senior engineers as needed.
• Collaborate closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to support system integration across airframe interfaces.
• Support structural validation efforts including coupon testing, subcomponent testing, and system-level verification.
• Generate high-quality design documentation, drawings, interface definitions, and analysis reports in compliance with aerospace standards.
• Partner with manufacturing and flight test teams to resolve build issues and support hardware through test and deployment.
• Participate in design reviews and technical discussions, presenting work clearly and incorporating feedback effectively.
• Continuously improve personal 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 related discipline.
• 5+ 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 (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 get a S//SAR level security clearance desired.

Preferred qualifications:

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

$130,000 - $200,000 a year

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.

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed toequal 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.