Staff Engineer, Aircraft Configuration Design (R5830)

Shield; San Diego (CA); On-site; USD 120,000 - 160,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

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

This role suits a mechanical or aerospace engineer with passion for multidisciplinary systems, rapid prototyping, and defense technology in a fast‑paced environment.

Qualifications

• Bachelor’s degree in Aerospace, Mechanical, or Systems Engineering (or related field).
• 7+ years in aircraft design, configuration layout, or airframe integration.

Responsibilities

• Assist in conceptual and preliminary design of UAV configurations.
• Support sizing, weight estimation, and trade studies for airframes.
• Collaborate with mechanical, electrical, propulsion, and avionics teams for integration.

Skills

CAD modeling

Aero/structural design

FEA/CFD basics

weight & balance

cross-functional teamwork

clear communication

Education

Bachelor’s in Aerospace/Mechanical/Systems Eng

Master’s preferred

Tools

NX

SolidWorks

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-BATaircraft, 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).
• 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 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

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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.