Staff Engineer, Aircraft Configuration Design (R5830)

Shield AI; Northern, San Diego (KY, CA); Hybrid; USD 144,000 - 210,000; Full time

Job summary

Shield AI seeks an Aircraft Configuration Design Engineer to advance next‑gen autonomous UAVs. You will design, optimize, and integrate aircraft configurations, aligning aerodynamics, structures, propulsion, and mission systems for manufacturability and operation.

The role suits a mechanical or aerospace engineer skilled in multi‑disciplinary integration, iterative prototyping, and working in a defense tech environment. Competitive salary, benefits, and equity offered.

Qualifications

• Bachelor’s degree in Aerospace, Mechanical, or Systems Engineering (or related field).
• 5 years of experience in aircraft design, configuration layout, or airframe integration.
• Proficiency in CAD modeling (NX, SolidWorks, or similar).
• Basic understanding of aircraft aerodynamics, structures, and propulsion system integration.
• Ability to perform basic FEA, CFD, or weight & balance assessments.
• Strong problem-solving skills and attention to detail; crossfunctional teamwork.
• Excellent communication and technical documentation skills.
• Active Secret clearance.

Responsibilities

• Assist in conceptual and preliminary design of UAV platforms, ensuring optimal configurations.
• Support aircraft sizing, weight estimation, and trade studies for airframe configurations.
• Collaborate with mechanical, electrical, propulsion, and avionics teams for system integration.
• Develop and refine 3D CAD models of aircraft structures and subsystems.
• Perform basic aerodynamic and structural analyses to assess feasibility and performance.
• Participate in design reviews, trade studies, and prototype development efforts.
• Support rapid prototyping and wind tunnel testing of scaled models.
• Assist in requirements development, documentation, and verification planning for subsystems.
• Ensure designs meet manufacturing feasibility and aerospace standards.
• Work with manufacturing to transition from concept to prototype and production.

Skills

CAD modeling

NX

SolidWorks

FEA

CFD

Weight & balance

Cross-functional teamwork

Technical documentation

Security clearance

Education

Bachelor’s degree in Aerospace/Mechanical/Systems Engineering

Master’s degree in Aerospace/Mechanical/Systems Engineering

Tools

CAD/CAE 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 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 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 flightcritical 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).
• 5 years of 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 crossfunctional teams.
• Excellent communication and technical documentation skills.
• Active Secret clearance

Preferred qualifications:

• Master’s degree in Aerospace, Mechanical, or Systems Engineering (or related field).
• Experience with unmanned aerial vehicle (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

$144,000 - $210,000 a year

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. Please speak to your talent acquisition representative for more information.

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed toequal 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.