Senior UAV Structural Analyst: FEA, Composites & Testing

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 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.