Senior Staff Aerostructures Engineer — Lead UAV Structures

Shieldai; Dallas (TX); On-site; USD 150,000 - 190,000; Full time

Job summary

Shield AI is seeking a Senior Staff Aerostructures Design Engineer to lead the development of structural systems for our next-generation autonomous aircraft.

As a senior mechanical engineer, you will own the design lifecycle from concept through production, applying FEA and DFMA to ensure performance, manufacturability, and mission readiness.

Collaborate with aero, propulsion, avionics, and manufacturing teams while mentoring others and driving design reviews and certification readiness.

Qualifications

• 10+ years in aircraft structural design
• Expertise in composite and metallic structures
• Proficient with DFMA, GD&T, tolerance stackups
• Experience with design reviews and verification
• Strong leadership and cross-functional collaboration

Responsibilities

• Lead design and development of structural components for UAV platform
• Own the structural design lifecycle from concept to drawing release
• Use FEA tools for linear and nonlinear analysis and margin assessment
• Collaborate with aerodynamics, propulsion, avionics, and manufacturing teams
• Lead material selection discussions focusing on composites and aluminum alloys
• Participate in design reviews and technical decision-making forums
• Oversee structural validation testing (coupon-level to full-system)
• Develop design documentation and verification plans compliant with MIL-STD/FAA
• Mentor junior engineers and review work for technical rigor
• Partner with manufacturing and flight test teams for production transition
• Drive improvements in design processes, configuration management, and workflows

Skills

Technical leadership

Cross-functional collaboration

Strong communication

Security clearance

Ownership mindset

Education

Master's or higher in Mechanical/Aerospace Engineering

Bachelor's in Mechanical/Aerospace Engineering

Tools

NX CAD

CATIA

SolidWorks

ANSYS

Abaqus

NASTRAN

Job description

Shield AI is seeking a Senior Staff Aerostructures Design Engineer to lead the development of structural systems for our next-generation autonomous aircraft.

As a senior mechanical engineer, you will own the design lifecycle from concept through production, applying FEA and DFMA to ensure performance, manufacturability, and mission readiness.

Collaborate with aero, propulsion, avionics, and manufacturing teams while mentoring others and driving design reviews and certification readiness.