Senior Aerostructures Design Engineer (R5158)

Shieldai; Seattle (WA); On-site; USD 120,000 - 160,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

Shield AI seeks an experienced aerospace structural engineer to design and release structural components for its next-generation UAV platform. You will perform CAD modeling, hand calculations, and collaborate across aerodynamics, propulsion, avionics, and manufacturing to ensure robust system integration.

The role requires 5+ years in aircraft structures, familiarity with composites and metals, and CAD tools like NX/CATIA/SolidWorks.

Qualifications

• Bachelors or Masters in Mechanical or Aerospace Engineering.
• 5+ years in aircraft structural design or related aerospace structures.
• Experience releasing structural components in development or production.
• Knowledge of composite and metallic structures with fasteners and bonded joints.
• Proficient in CAD tools: NX, CATIA, SolidWorks (or similar).
• Understanding of GD&T, tolerance stackups, and DFMA.
• Strong written and verbal technical communication skills.
• Ability to obtain S//SAR level security clearance.
• Experience with UAV, DoD, or aerospace vehicle programs.
• Exposure to composite design and manufacturing methods.
• Experience using FEA tools (ANSYS, Abaqus, NASTRAN) for linear analysis.

Responsibilities

• Design and develop structural components for UAV platforms.
• Conduct conceptual, CAD modeling, detailed design, and drawing release.
• Perform hand calculations with limited FEA guidance.
• Collaborate with aerodynamics, propulsion, avionics, payload, and manufacturing teams.
• Support structural validation: coupon testing, subcomponent testing, system verification.
• Generate design docs, drawings, interfaces, and analysis reports.
• Work with manufacturing and flight test to resolve build issues.
• Participate in design reviews and present work clearly.
• Continuously improve structural layout, joints, tolerancing, and optimization.

Skills

Aerospace structural design

GD&T & DFMA

Technical communication

Fast-paced engineering

FEA experience

Education

Bachelors or Masters in Mechanical/Aerospace Eng

MS in Aerospace or Mechanical Eng

Tools

NX

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-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.

• 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.
• 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.
• 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

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.