Staff Aerostructures Design Engineer (R5160)

The Rundown AI, Inc.; Dallas (TX); On-site; USD 90,000 - 120,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

The Rundown AI, Inc. is seeking a Staff Aerostructures Design Engineer in Dallas, Texas, to support the development of structural components for autonomous aircraft. This role involves the design and development of high-performance components while collaborating cross-functionally to ensure design integrity. The ideal candidate will have a degree in Mechanical or Aerospace Engineering and substantial experience in structural design.

This position offers a comprehensive package including salary, bonuses, and benefits, while contributing to innovative aerospace solutions.

Qualifications

• 8+ years of experience in aircraft structural design or closely related aerospace structures.
• Experience designing and releasing structural components in development or production environments.
• Ability to get a S//SAR level security clearance desired.

Responsibilities

• Design and develop structural components and assemblies for UAV platforms.
• Execute all stages of the design lifecycle including initial CAD modeling.
• Collaborate closely with aerodynamics, propulsion, avionics, and manufacturing teams.

Skills

Aircraft structural design

CAD tools (NX, CATIA, SolidWorks)

Technical communication skills

Understanding of GD&T

Education

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

Tools

ANSYS

Abaqus

NASTRAN

Job description

Job Description

Shield AI is seeking a Staff Aerostructures Design Engineer to support the development of structural components for our next-generation autonomous aircraft. As a key contributor on the Mechanical Engineering team, you will design and develop high-performance structural components from concept through production release.

You’ll work cross-functionally to ensure structural integrity, manufacturability, and system integration across one of the most advanced autonomous aircraft platforms being built today. This role is ideal for an aerospace mechanical engineer who thrives in hands‑on design environments and is eager to take increasing ownership of flight‑critical designs.

What you’ll do

• 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 closely 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.

Required qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related discipline.
• 8+ 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.
• Ability to get a S//SAR level security clearance desired.

Preferred qualifications

• M.S. degree in Aerospace or Mechanical Engineering.
• Experience supporting UAV, DoD, or aerospace vehicle programs.
• Familiarity with aerospace standards (MIL‑STD, ASME Y14.5, FAA).
• Experience supporting hardware through test, failure analysis, and design iteration.
• Exposure to composite design and manufacturing methods.
• Experience using FEA tools (ANSYS, Abaqus, NASTRAN, or similar) for linear structural analysis.

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.

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.