Staff Engineer, Aircraft Configuration Design

Shield AI; Seattle (WA); On-site; USD 120,000 - 170,000; Full time

Job summary

Shield AI is seeking an Aircraft Configuration Design Engineer to support the development of next-generation autonomous UAVs. You will assist in the design, optimization, and integration of aircraft configurations, ensuring harmonized aerodynamics, structures, propulsion, and mission systems for performance and manufacturability.

This role suits a mechanical or aerospace engineer passionate about cutting-edge aircraft design, multi-disciplinary systems integration, and rapid prototyping in a

Qualifications

• Bachelor’s degree in aerospace, mechanical, or systems engineering.
• 7+ years of aircraft design, configuration layout, or airframe integration.
• Proficiency in CAD modeling (NX, SolidWorks).
• Understanding of aerodynamics, structures, and propulsion integration.
• Ability to perform basic FEA, CFD, or weight & balance assessments.
• Strong problem-solving skills, attention to detail, and cross-functional teamwork.
• Excellent communication and technical documentation skills.

Responsibilities

• Assist in conceptual and preliminary design of Shield AI’s newest UAV platforms, ensuring optimal aerodynamic and structural configurations.
• Support aircraft sizing, weight estimation, and trade studies to evaluate different airframe configurations.
• Work with multi-disciplinary engineering teams to ensure seamless system integration.
• Develop and refine 3D CAD models of aircraft structures, subsystems, and flight critical components.
• Perform basic aerodynamic and structural analysis using computational tools to assess feasibility and performance impacts.
• Participate in design reviews, system trade studies, and prototype development efforts.
• Support rapid prototyping and wind tunnel testing of scaled models to validate design concepts.
• Assist in requirements development, documentation, and verification planning for aircraft subsystems.
• Ensure designs comply with manufacturing feasibility, mission requirements, and aerospace industry standards.
• Work closely with manufacturing and production teams to transition designs from concept to prototype and full-scale production.

Skills

Problem-solving

Communication

Documentation

Education

Bachelor’s degree in Aerospace, Mechanical, or Systems Engineering

Master’s degree (preferred)

Tools

NX

SolidWorks

CAD tools

Job description

Shield AI is a venture-backed defense-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software, V-BAT and X-BAT aircraft, and Aechelon simulation and synthetic reality technologies. With offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific, Shield AI’s technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description:

Shield AI is seeking an Aircraft Configuration Design Engineer to support the development of next-generation autonomous unmanned air vehicles (UAVs'). In this role, you will assist in the design, optimization, and integration of aircraft configurations, ensuring that vehicle aerodynamics, structures, propulsion, and mission systems are harmonized for performance, manufacturability, and operational effectiveness.

This position is ideal for a mechanical or aerospace engineer with a passion for cutting edge aircraft design, multi-disciplinary systems integration, and iterative prototyping in a fast-paced defense technology environment.

What you'll do:

• Assist in the conceptual and preliminary design of Shield AI’s newest UAV platforms, ensuring optimal aerodynamic and structural configurations.
• Support aircraft sizing, weight estimation, and trade studies to evaluate different airframe configurations.
• Work with multi-disciplinary engineering teams (mechanical, electrical, propulsion, avionics) to ensure seamless system integration.
• Develop and refine 3D CAD models of aircraft structures, subsystems, and flight critical components.
• Perform basic aerodynamic and structural analysis using computational tools to assess feasibility and performance impacts.
• Participate in design reviews, system trade studies, and prototype development efforts.
• Support rapid prototyping and wind tunnel testing of scaled models to validate design concepts.
• Assist in requirements development, documentation, and verification planning for aircraft subsystems.
• Ensure designs comply with manufacturing feasibility, mission requirements, and aerospace industry standards.
• Work closely with manufacturing and production teams to transition designs from concept to prototype and full-scale production.

Required qualifications:

• Bachelor’s degree in Aerospace, Mechanical, or Systems Engineering (or related field).
• Typically requires a minimum of 7 years of related experience in aircraft design, configuration layout, or airframe integration.
• Proficiency in CAD modeling (NX, SolidWorks, or similar) for airframe and structural design.
• Basic understanding of aircraft aerodynamics, structures, and propulsion system integration.
• Ability to perform basic FEA, CFD, or weight & balance assessments.
• Strong problem-solving skills, attention to detail, and ability to work in cross functional teams.
• Excellent communication and technical documentation skills.

Preferred qualifications:

• Master’s degree in Aerospace, Mechanical, or Systems Engineering (or related field).
• Experience with UAV design or aircraft conceptual design.
• Familiarity with aircraft performance modeling, stability & control, and flight dynamics.
• Hands-on experience with rapid prototyping, wind tunnel testing, or flight hardware development.
• Knowledge of manufacturing techniques, composite materials, and aerospace structural design principles.
• Experience working in a fast-paced, high-tech startup or defense environment.
• Active TS clearance or ability to gain a TS clearance.