Senior Aerostructures Stress Lead | Aircraft FEA Expert

Shield; Dallas (TX); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Bonus

Equity

Benefits

Job summary

Shield AI in Dallas seeks an experienced structural analysis engineer to lead UAV airframe analyses, FEM development, and cross-functional collaboration. You will drive margins, weight optimization, and test correlation while mentoring junior analysts and guiding design decisions in a fast-paced aircraft program.

The role emphasizes advanced hand calculations, composite structures expertise, and the ability to present results to engineering leadership. A security clearance is desirable.

Qualifications

• BS in Mechanical or Aerospace Engineering or related field required.
• 10+ years in structural analysis, aircraft structures, or aerospace systems.
• Strong experience with FEA tools (ANSYS, NASTRAN, HyperWorks).
• Advanced hand calculations for strength, stability, fatigue and damage tolerance.
• Experience with composite and lightweight aerospace structures.
• Experience supporting structural testing and flight test validation.
• Ability to lead complex technical workstreams and influence design decisions.
• Strong communication skills for presenting findings to leadership.
• Security clearance at S//SAR level desired.

Responsibilities

• Lead structural analysis efforts for UAV airframes and major substructures.
• Define FEM approaches, load cases, assumptions, and margin assessments.
• Perform static, modal, fatigue, vibration, and damage-tolerance analyses.
• Establish hand calculations, model validation, and analysis-to-test correlation.
• Drive structural optimization balancing performance, weight, cost, and manufacturability.
• Support structural test strategy and correlate results with analysis.
• Review deliverables, test reports, and documentation for design reviews.
• Mentor and guide structural analysts across experience levels.
• Collaborate with design, loads, aero, propulsion, and systems teams.
• Contribute to evolving analysis methodologies and standards.

Skills

Leadership

Communication

Mentoring

Analytical thinking

Decision making

Problem solving

Education

BS in Mechanical or Aerospace Engineering

Master’s or PhD desired

Tools

ANSYS

NASTRAN

HyperWorks

Job description

Shield AI in Dallas seeks an experienced structural analysis engineer to lead UAV airframe analyses, FEM development, and cross-functional collaboration. You will drive margins, weight optimization, and test correlation while mentoring junior analysts and guiding design decisions in a fast-paced aircraft program.

The role emphasizes advanced hand calculations, composite structures expertise, and the ability to present results to engineering leadership. A security clearance is desirable.