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Shield AI, a venture-backed defense-tech company, is seeking a Staff Aerostructures Design Engineer to design and develop structural components and assemblies for next-generation UAV platforms. This is a senior individual contributor role with company-wide technical scope in structural design.
You will execute all stages of the design lifecycle from conceptual development through detailed CAD modeling, analysis, and drawing release. Responsibilities include performing hand calculations and basic FEA analysis (with guidance from senior engineers), collaborating across aerodynamics, propulsion, avionics, payload, and manufacturing teams to support system integration, and supporting structural validation through coupon testing, subcomponent testing, and system-level verification. You will generate high-quality design documentation, drawings, and analysis reports in compliance with aerospace standards, partner with manufacturing and flight test teams to resolve build issues, and participate actively in design reviews and technical discussions. The role emphasizes continuous improvement in structural layout, joints, fasteners, tolerancing, and structural optimization.
Shield AI's products include Hivemind autonomy software, V-BAT and X-BAT aircraft, and Aechelon simulation technologies, with operations worldwide across the U.S., Europe, the Middle East, and Asia-Pacific.
REQUIREMENTS:
- Bachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, or related discipline
- 5+ 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
PREFERRED:
- 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
