Aircraft Structures Engineer (R3263)

Founded in 2015, Shield AI is a venture-backed defense technology company with the mission of protecting service members and civilians with intelligent, autonomous systems. Its products include Hivemind Enterprise—EdgeOS, Pilot, Commander, and Forge—as well as V-BAT and Sentient Vision Systems (wide-area motion imaging software). With offices in San Diego, Dallas, Washington, D.C., Abu Dhabi (UAE), Kyiv (Ukraine), and Melbourne (Australia), Shield AI’s technology actively supports U.S. and allied operations worldwide.  For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X and Instagram.    

Job Description:

Join Shield AI in shaping the future of autonomous aircraft! We’re looking for an Aircraft Structures Engineer to push the boundaries of UAV performance through cutting-edge structural design, analysis, and testing. In this role, you’ll collaborate with top-tier Mechanical, Systems, Propulsion, and Aerospace Engineers to ensure our lightweight, high-performance aircraft are built for speed, endurance, and reliability.

You’ll play a key role in designing, analyzing, testing, and optimizing airframe structures and components, ensuring they meet the highest standards for performance, weight, and safety. This is a unique opportunity to deepen your expertise in design, finite element analysis (FEA), composite materials, mechanical testing, and aircraft loads analysis—all within a fast-paced, high-tech aerospace environment where innovation takes flight.

If you have a passion for cutting-edge aircraft design, come help us build the future of intelligent aviation!

What you'll do:

• Lead the conceptualization and structural development of clean-sheet aircraft designs, ensuring innovative and mission-driven engineering solutions.
• Integrate aerodynamics, propulsion, and structural requirements from the ground up to create next-generation UAV platforms that push performance boundaries.
• Develop and refine cutting-edge finite element models (FEM) to push the limits of UAV structural performance.
• Execute high-impact static, modal, fatigue, and vibration analyses to ensure our aircraft can withstand extreme conditions.
• Perform critical hand calculations to validate FEA results, guaranteeing precision, accuracy, and structural reliability.
• Design to optimize airframe structures, striking the perfect balance between weight, strength, and manufacturability.
• Drive the development of innovative test plans for structural validation, including quasi-static, vibration, and shock testing.
• Analyze real-world flight telemetry and structural test data to refine models and enhance predictive accuracy.
• Define essential load cases, material properties, and design margins to fortify UAV airframe and mechanical components.
• Deliver impactful structural analysis reports and technical recommendations that shape engineering decisions.
• Collaborate across disciplines to align structural integrity with overall system performance, ensuring mission success.
• Advance the future of UAV design by continuously improving structural analysis methodologies, tools, and best practices.

Required qualifications:

• B.S. in Mechanical Engineering, Aerospace Engineering, or a related field with a passion for structural innovation.
• 5-10 years of hands-on experience in aircraft design, structural analysis, finite element modeling, or aircraft loads analysis.
• Proficiency in industry-leading FEA tools such as ANSYS, NASTRAN, HyperWorks, or similar.
• Exceptional ability to perform hand calculations for structural strength, stability, and fatigue analysis with precision.
• Deep understanding of composite materials and lightweight aerospace structures for high-performance UAVs.
• Experience with advanced mechanical testing methods, including static, vibration, and fatigue testing.
• Strong command of data analysis tools such as Excel, MATLAB, Python, or similar for data-driven engineering.
• Proven problem-solving skills, meticulous attention to detail, and a collaborative mindset to thrive in a dynamic team environment.

Preferred qualifications:

• Master’s degree in Mechanical or Aerospace Engineering.
• Experience in aircraft structural design, UAV airframe development, or aerospace testing.
• Hands-on experience with structural testing, modal analysis, or composite modeling.
• Exposure to CAD software (NX, SolidWorks) and PLM tools (Teamcenter or similar).
• Understanding of aerospace industry standards, structural certification processes, and material selection.

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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.

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Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal 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.