Senior UAV Structural Design Engineer

Shieldai; Dallas (TX); On-site; USD 120,000 - 190,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

Shield AI in Dallas, TX, seeks a Senior Aerostructures Design Engineer to lead the design of structural components for next‑generation UAVs from concept through production release. You will design, analyze, document, and integrate airframe structures, working with aerodynamics, propulsion, avionics, and manufacturing teams to ensure performance and manufacturability.

A strong background in aerospace structures and CAD is required.

Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related discipline.
• 5+ years of experience in aircraft structural design or closely related aerospace structures.
• Experience designing and releasing structural components in development or production environments.
• Working knowledge of composite and metallic structures, including fasteners, bonded joints, and load paths.
• Proficiency in CAD tools (NX, CATIA, SolidWorks, or similar).
• Understanding of GD&T, tolerance stackups, and DFMA principles.
• Strong written and verbal technical communication skills.
• Demonstrated ability to operate in fast-paced, high-ownership engineering environments.

Responsibilities

• Design and develop structural components and assemblies for Shield AI’s next-generation UAV platform, supporting both primary and secondary aircraft structures.
• Execute all stages of the design lifecycle including conceptual development, initial CAD modeling, detailed design, and drawing release.
• Perform hand calculations for stress or strain with limited basic FEA analysis, with guidance from senior engineers as needed.
• Collaborate with aerodynamics, propulsion, avionics, payload, and manufacturing teams to support system integration across airframe interfaces.
• Support structural validation efforts including coupon testing, subcomponent testing, and system-level verification.
• Generate high-quality design documentation, drawings, interface definitions, and analysis reports in compliance with aerospace standards.
• Partner with manufacturing and flight test teams to resolve build issues and support hardware through test and deployment.
• Participate in design reviews and technical discussions, presenting work clearly and incorporating feedback effectively.
• Continuously improve personal technical depth in structural layout, joints, fasteners, tolerancing, and structural optimization.

Skills

Structural design

Aerospace engineering

FEM analysis

Technical communication

Security clearance

Education

Bachelor's in Mechanical or Aerospace Eng

Master's in Aerospace or Mechanical Eng

Tools

NX

CATIA

SolidWorks

ANSYS

Job description

Shield AI in Dallas, TX, seeks a Senior Aerostructures Design Engineer to lead the design of structural components for next‑generation UAVs from concept through production release. You will design, analyze, document, and integrate airframe structures, working with aerodynamics, propulsion, avionics, and manufacturing teams to ensure performance and manufacturability.

A strong background in aerospace structures and CAD is required.