Senior Staff Aerostructures Design Engineer (R5846)

Shield; San Diego (CA); On-site; USD 170,000 - 260,000; Full time

Benefits offered by this job

Equity

Bonus

Benefits

Job summary

Shield AI is seeking an experienced structural engineer to lead the design of next‑gen UAV airframes, focusing on primary and secondary structures. You will own the design lifecycle from concept through drawing release and work with cross‑functional teams to ensure successful system integration.

You will perform linear and nonlinear analyses, guide margin assessments, and contribute to design reviews, material selection, and validation testing. Mentorship and rigorous documentation are expected.

Qualifications

• 10+ years of experience in aircraft structural design.
• Experience with composite and metallic structures and material behavior.
• Proficiency with NX, CATIA, or SolidWorks and FEA tools (ANSYS, Abaqus, NASTRAN).
• Experience with DFMA, GD&T, tolerance stackups and structural layouts.
• Ability to obtain a S//SAR level security clearance.
• Strong communication and cross-functional leadership.

Responsibilities

• Lead design and development of structural components for Shield AI’s next-gen UAV platform.
• Own lifecycle from concept to drawing release with traceability.
• Perform and guide linear/nonlinear structural analysis and margin assessments.
• Collaborate with aerodynamics, propulsion, avionics and manufacturing teams.
• Lead material selection focusing on composites and aluminum alloys.
• Lead design reviews and technical decision forums.
• Oversee structural validation testing from coupon to full-system.
• Develop design documentation, analysis reports, and verification plans per MIL-STD/FAA/Shield standards.
• Mentor junior engineers and ensure manufacturability.
• Transition designs to production and field deployment.
• Identify opportunities to improve design processes and workflows.

Skills

Aircraft structural design

Composite and metallic structures

DFMA

GD&T

FEA analysis

Technical leadership

Clear communication

Education

Bachelor’s or Master’s degree in Mechanical or Aerospace Engineering

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-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:

We are seeking a highly motivated engineer to support the design, development, integration, and fielding of a next-generation autonomous aircraft system. This position requires a balance of technical rigor, rapid decision‑making, and hands‑on engineering to efficiently transition concepts into operational capability. The ideal candidate is comfortable solving complex problems, taking ownership, working within an accelerated aircraft development environment, and is motivated by getting meaningful capability into the hands of operators quickly.

What you'll do:

• Lead the design and development of structural components and assemblies for Shield AI’s next-gen UAV platform, with a focus on primary and secondary aircraft structures.
• Own the structural design lifecycle including concept generation, CAD modeling, detail design, and drawing release, ensuring high quality and traceability.
• Use FEA tools to perform and guide linear and nonlinear structural analysis, stress analysis, and margin assessment under operational loads and edge cases.
• Work closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to ensure seamless system integration across airframe and subsystem interfaces.
• Support and lead efforts in material selection, focusing on composites, aluminum alloys, and advanced manufacturing approaches suited to mission and environment.
• Participate in and lead design reviews, architecture discussions, and technical decision‑making forums related to structural systems.
• Oversee the design and execution of structural validation testing, including coupon‑level, subcomponent, and full‑system testing.
• Guide the development of design documentation, analysis reports, interface definitions, and verification plans in compliance with MIL‑STD, FAA, and internal Shield AI standards.
• Mentor junior engineers and review team members’ work for technical rigor, performance, and manufacturability.
• Collaborate with the manufacturing and flight test teams to transition designs from engineering to production and field deployment.
• Identify opportunities to improve design processes, configuration management, and team workflows for increased engineering velocity and design quality.

Required qualifications:

• Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• 10+ years of experience in aircraft structural design, with demonstrated 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.
• Expertise in CAD tools (NX, CATIA, or SolidWorks) and FEA tools (ANSYS, Abaqus, NASTRAN, or similar).
• Experience conducting or overseeing stress analysis, fatigue analysis, and design optimization.
• Strong working knowledge of DFMA, GD&T, tolerance stackups, and structural layout principles.
• Clear, concise technical communication skills and experience leading cross‑functional engineering efforts.
• A track record of technical excellence, high ownership, and a mission‑driven mindset in challenging engineering environments.
• Ability to get a S//SAR level security clearance desired.

Preferred qualifications:

• M.S. degree in Aerospace or Mechanical Engineering.
• Strong NX CAD skills
• Experience supporting or leading Group 3–5 UAV, DoD aircraft, or high‑performance aerospace vehicle programs.
• Knowledge of aerospace standards (MIL‑STD, ASME Y14.5, FAA FARS) and certification pathways.
• Prior experience in flight vehicle integration, manufacturing liaison, or production support.
• Familiarity with model‑based engineering, digital twin development, or configuration management tools.
• Demonstrated experience in failure analysis, design iteration, and test correlation.
• Previous work in startup, R&D, or high‑growth defense environments where agility and innovation are key.

$170,000 - $260,000 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. 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.