Principal Aerostructures Design Engineer (R5163)

Shield AI is seeking a Principal Aerostructures Design Engineer to play a critical role in the development of structural components for our next-generation autonomous aircraft. As a senior member of the Mechanical Engineering team, you will own the design and development of high-performance structural systems, from clean-sheet concepts to production-ready hardware. You’ll work across disciplines to ensure structural integrity, manufacturability, and mission-readiness in one of the most advanced autonomous aircraft platforms being built today. This role is ideal for an experienced aerospace mechanical engineer who thrives in fast-paced, high-ownership environments and is passionate about building systems that matter.

Responsibilities

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

Requirements

Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline; 15+ 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

Nice to have

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

Benefits

Bonus; Benefits; Equity