Senior UAV Structural Analyst FEA, Airframes & Testing

Lever, Inc.; Northern (KY); Hybrid; USD 110,000 - 210,000; Full time

Job summary

Shield AI is seeking a Sr. Structural Analyst to support the analysis and testing of advanced UAVs. You will work with Mechanical Systems, Propulsion, and other engineering teams to ensure airframe integrity while balancing weight and safety requirements.

Ideal candidates have 5+ years in structural analysis and hands-on experience with FEA tools, composites, and mechanical testing. The role offers opportunities to influence design and verification in a fast‑paced aerospace environment.

Qualifications

• 5+ years in structural analysis or loads analysis; aerospace background preferred.
• Experience with FEA tools and hand calculations for strength and stability.
• Knowledge of composite materials and lightweight aerospace structures.
• Proficient in data analysis tools (Excel, MATLAB, Python).
• Ability to obtain a S//SAR clearance is desirable.

Responsibilities

• Build and refine FEMs to evaluate UAV structural performance.
• Perform static, modal, fatigue, and vibration analyses.
• Validate FEA with hand calculations for reliability.
• Collaborate with design engineers to optimize airframe structures.
• Develop structural test plans for validation and testing.
• Analyze flight telemetry and test data to improve models.
• Define load cases, materials, and design margins for airframes.
• Prepare and present structural analysis reports to teams.
• Ensure structural requirements align with system goals.
• Contribute to continuous improvement of analysis methods.

Skills

FEA Tools

Structural Analysis

Loads Analysis

Data Analysis

Security Clearance (desired)

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 seeking a Sr. Structural Analyst to support the analysis and testing of advanced UAVs. You will work with Mechanical Systems, Propulsion, and other engineering teams to ensure airframe integrity while balancing weight and safety requirements.

Ideal candidates have 5+ years in structural analysis and hands-on experience with FEA tools, composites, and mechanical testing. The role offers opportunities to influence design and verification in a fast‑paced aerospace environment.