Senior Aerostructures Design Lead for Next-Gen UAVs

Shield AI

San Diego (CA)

On-site

USD 170,000 - 260,000

Full time

14 days+

A complete application in a minute

Tailored resume and cover letter, ready to send.

Get past ATS filters

Job summary

Shield AI seeks an experienced structural engineer to design, analyze, and validate the airframe for a next‑gen UAV platform. You will own the full structural lifecycle, drive DFM considerations, and collaborate with aerodynamics, propulsion, avionics, and manufacturing to deliver robust, certifiable airframes.

The role requires 10+ years in aircraft structural design, expertise in composites and metals, and strong CAD/FEA proficiency.

Qualifications

Bachelor’s or Master’s degree in Mechanical or Aerospace Engineering or related discipline.
10+ years of aircraft structural design experience with 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.
Experience with CAD tools (NX, CATIA, SolidWorks) and FEA tools (ANSYS, Abaqus, NASTRAN).
Experience with stress/fatigue analysis and design optimization.
Knowledge of DFMA, GD&T, tolerance stackups, and structural layouts.
Strong technical communication and leadership across cross-functional teams.
Ability to obtain a S//SAR level security clearance preferred.

Responsibilities

Lead design and development of structural components for Shield AI’s UAV platform.
Own the structural design lifecycle from concept to drawing release with traceability.
Perform and guide linear and nonlinear structural analysis and margin checks.
Collaborate with aerodynamics, propulsion, avionics, payload, and manufacturing teams for system integration.
Lead material selection focusing on composites and aluminum alloys and advanced manufacturing approaches.
Guide design reviews, architecture discussions, and technical decision-making for structural systems.
Oversee structural validation testing from coupon to full-system levels.
Develop design documentation, analysis reports, interfaces, and verification plans per MIL-STD, FAA, and Shield AI standards.
Mentor junior engineers and ensure rigorous, manufacturable designs.
Work with production and flight test teams to transition designs to production and field deployment.