Senior Engineer, Structural Analyst (R6027)

Shield; San Diego (TX); On-site; USD 110,000 - 210,000; Full time

Job summary

Shield AI is seeking a Sr. Structural Analyst to support UAV design, analysis, and testing. You will work with mechanical systems and propulsion teams to ensure airframe integrity while balancing weight and safety requirements.

The role emphasizes experience in FEA, composite and metallic materials, and mechanical testing in a fast-paced aerospace environment. A security clearance is desirable and examples of collaboration with design teams are valued.

Qualifications

• 5+ years in structural analysis or aircraft loads; or 3+ years with MS.
• Experience using FEA tools: FEMAP, NASTRAN, HyperWorks, ANSYS, Patran or similar.
• Ability to perform hand calculations for strength and stability.
• Knowledge of composite materials and lightweight aerospace structures.
• Familiarity with mechanical testing methods (static, vibration, fatigue).
• Proficiency with data analysis tools (Excel, MATLAB, Python).
• Strong problem-solving, attention to detail, and teamwork.
• Ability to obtain a S//SAR security clearance is desired.

Responsibilities

• Build and refine finite element models to evaluate UAV component performance.
• Perform static, modal, fatigue, and vibration analyses to assess stress and deformation.
• Conduct hand calculations to validate FEA results for reliability.
• Collaborate with design engineers to optimize airframe structures balancing weight and strength.
• Support test plan development for structural validation (quasi-static, vibration, shock).
• Analyze flight telemetry and test data to improve modeling accuracy.
• Define load cases, material properties, and design margins for airframe components.
• Document and present structural analysis findings to engineering teams.
• Collaborate with cross-functional teams to align structural requirements with system goals.
• Contribute to improving analysis methodologies and tools.

Skills

FEA modeling

Loads analysis

Python

MATLAB

Excel

Teamwork

Data analysis

Education

B.S. in Mechanical or Aerospace Engineering

M.S. in Mechanical or Aerospace Engineering

Tools

FEMAP

NASTRAN

HyperWorks

ANSYS

Patran

NX

Catia

SolidWorks

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 Sr. Structural Analyst to support the analysis and testing of advanced UAVs. In this role, you will work closely with Mechanical Systems, Propulsion, Mechanisms, and other engineering disciplines to ensure the structural integrity of our lightweight, high-performance aircraft. You will contribute to the design, analysis, testing, and optimization of airframe structures and components, ensuring they meet performance, weight, and safety requirements.

This role is ideal for engineers with 5+ years of experience looking to gain expertise in finite element analysis (FEA), composite and metallic materials, and mechanical testing in a fast-paced, high‑tech aerospace environment.

What you’ll do

• Assist in building and refining finite element models (FEM) to evaluate the structural performance of UAV components.
• Perform static, modal, fatigue, and vibration analyses to assess stress, deformation, and durability.
• Conduct hand calculations to validate FEA results, ensuring accuracy and structural reliability.
• Work with design engineers to optimize airframe structures, balancing weight, strength, and manufacturability.
• Support the development of test plans for structural validation, including quasi‑static, vibration, and shock testing.
• Analyze flight telemetry and structural test data to improve modeling accuracy and correlate predictions with real‑world performance.
• Assist in defining load cases, material properties, and design margins for UAV airframe and mechanical components.
• Document and present structural analysis reports and technical recommendations to engineering teams.
• Collaborate with cross‑functional teams to ensure structural requirements align with system performance goals.
• Contribute to the continuous improvement of structural analysis methodologies, tools, and best practices.

Required qualifications

• 5+ years of experience in structural analysis, finite element modeling, or aircraft loads analysis AND B.S. in Mechanical Engineering, Aerospace Engineering, or related field. Alternatively, 3+ years of experience AND a M.S. in Mechanical or Aerospace Engineering
• Experience with FEA tools (FEMAP, NASTRAN, HyperWorks, ANSYS, Patran, or similar).
• Ability to perform hand calculations for structural strength and stability analysis.
• Knowledge of composite materials and lightweight aerospace structures.
• Familiarity with mechanical testing methods (static, vibration, and/or fatigue).
• Proficiency with data analysis tools (Excel, MATLAB, Python, or similar).
• Strong problem‑solving skills, attention to detail, and ability to work in a team environment.
• Ability to obtain a S//SAR level security clearance desired.

Preferred qualifications

• Experience in aircraft structural design, UAV airframe development, or aerospace testing.
• Hands‑on experience with structural testing.
• Exposure to CAD software (NX, Catia, SolidWorks) and PLM tools (Teamcenter or similar).
• Understanding of aerospace industry standards, structural certification processes, and material selection.
• Fatigue and damage tolerance (DaDT) experience including crack initiation and crack growth

$110,000 - $210,000 a year

San Diego, CA and Dallas, TX range: $110,000 - $170,000

Seattle, WA range: $140,000 - $210,000

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.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.