Staff Aerostructures Design Engineer — UAV Flight Structures

InvestedintheMission; San Diego (CA); On-site; USD 160,000 - 240,000; Full time

Job summary

Shield AI is seeking a Staff Aerostructures Design Engineer to shape the structural components of its next‑generation autonomous aircraft. You will lead design from concept to production, ensuring structural integrity, manufacturability, and seamless system integration across airframe interfaces.

You’ll perform hand calculations and engage with cross‑functional teams to validate designs, support testing, and deliver flight‑worthy hardware in a fast‑paced, high‑ownership environment.

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.

Responsibilities

• Design and develop structural components and assemblies for Shield AI's next-generation UAV platform.
• 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 for system integration.
• Support structural validation efforts including coupon testing, subcomponent testing, and system-level verification.
• Generate design documentation, drawings, interface definitions, and analysis reports compliant 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, incorporating feedback.

Skills

Aerospace structures

CAD software

GD&T

Technical communication

Security clearance desired

Education

Bachelor’s or Master’s in Mechanical or Aerospace Engineering

Tools

NX

CATIA

SolidWorks

ANSYS / Abaqus / NASTRAN

Job description

Shield AI is seeking a Staff Aerostructures Design Engineer to shape the structural components of its next‑generation autonomous aircraft. You will lead design from concept to production, ensuring structural integrity, manufacturability, and seamless system integration across airframe interfaces.

You’ll perform hand calculations and engage with cross‑functional teams to validate designs, support testing, and deliver flight‑worthy hardware in a fast‑paced, high‑ownership environment.