Staff Aerostructures Design Engineer (R5159)

Shield AI is seeking a Staff Aerostructures Design Engineer to support the development of structural components for our next-generation autonomous aircraft. As a key contributor on the Mechanical Engineering team, you will design and develop high-performance structural components from concept through production release.

You’ll work cross-functionally to ensure structural integrity, manufacturability, and system integration across one of the most advanced autonomous aircraft platforms being built today. This role is ideal for an aerospace mechanical engineer who thrives in hands-on design environments and is eager to take increasing ownership of flight-critical designs.

Design and develop structural components and assemblies for Shield AI’s next-generation UAV platform, supporting both primary and secondary aircraft structures.

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 closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to support system integration across airframe interfaces.

Support structural validation efforts including coupon testing, subcomponent testing, and system-level verification.

Generate high-quality design documentation, drawings, interface definitions, and analysis reports in compliance 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, presenting work clearly and incorporating feedback effectively.

Continuously improve personal technical depth in structural layout, joints, fasteners, tolerancing, and structural optimization.

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.

M.S. degree in Aerospace or Mechanical Engineering.

Experience supporting UAV, DoD, or aerospace vehicle programs.

Familiarity with aerospace standards (MIL-STD, ASME Y14.5, FAA).

Experience supporting hardware through test, failure analysis, and design iteration.

Exposure to composite design and manufacturing methods.

Experience using FEA tools (ANSYS, Abaqus, NASTRAN, or similar) for linear structural analysis