Senior Staff Aerostructures Design Engineer (R5846)

We are seeking a highly motivated engineer to support the design, development, integration, and fielding of a next-generation autonomous aircraft system. This position requires a balance of technical rigor, rapid decision-making, and hands-on engineering to efficiently transition concepts into operational capability. The ideal candidate is comfortable solving complex problems, taking ownership, working within an accelerated aircraft development environment, and is motivated by getting meaningful capability into the hands of operators quickly.

Lead the design and development of structural components and assemblies for Shield AI’s next-gen UAV platform, with a focus on primary and secondary aircraft structures.

Own the structural design lifecycle including concept generation, CAD modeling, detail design, and drawing release, ensuring high quality and traceability.

Use FEA tools to perform and guide linear and nonlinear structural analysis, stress analysis, and margin assessment under operational loads and edge cases.

Work closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to ensure seamless system integration across airframe and subsystem interfaces.

Support and lead efforts in material selection, focusing on composites, aluminum alloys, and advanced manufacturing approaches suited to mission and environment.

Participate in and lead design reviews, architecture discussions, and technical decision-making forums related to structural systems.

Oversee the design and execution of structural validation testing, including coupon-level, subcomponent, and full-system testing.

Guide the development of design documentation, analysis reports, interface definitions, and verification plans in compliance with MIL-STD, FAA, and internal Shield AI standards.

Mentor junior engineers and review team members’ work for technical rigor, performance, and manufacturability.

Collaborate with the manufacturing and flight test teams to transition designs from engineering to production and field deployment.

Identify opportunities to improve design processes, configuration management, and team workflows for increased engineering velocity and design quality.

Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.

10+ years of experience in aircraft structural design, with demonstrated ownership of components or systems in development, test, or production.

Deep understanding of composite and metallic structures, including material behavior, joints, and thermal/environmental effects.

Expertise in CAD tools (NX, CATIA, or SolidWorks) and FEA tools (ANSYS, Abaqus, NASTRAN, or similar).

Experience conducting or overseeing stress analysis, fatigue analysis, and design optimization.

Strong working knowledge of DFMA, GD&T, tolerance stackups, and structural layout principles.

Clear, concise technical communication skills and experience leading cross-functional engineering efforts.

A track record of technical excellence, high ownership, and a mission-driven mindset in challenging engineering environments.

Ability to get a S//SAR level security clearance desired.

M.S. degree in Aerospace or Mechanical Engineering.

Strong NX CAD skills

Experience supporting or leading Group 3–5 UAV, DoD aircraft, or high-performance aerospace vehicle programs.

Knowledge of aerospace standards (MIL-STD, ASME Y14.5, FAA FARS) and certification pathways.

Prior experience in flight vehicle integration, manufacturing liaison, or production support.

Familiarity with model-based engineering, digital twin development, or configuration management tools.

Demonstrated experience in failure analysis, design iteration, and test correlation.

Previous work in startup, R&D, or high-growth defense environments where agility and innovation are key.