Senior Aerostructures Design Engineer; R5161 Security Clearance

Position: Senior Staff Aerostructures Design Engineer (R5161) with Security Clearance
Founded in 2015, Shield AI is a venture-backed defense-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software and V-BAT and X-BAT aircraft. With offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific, Shield AI's technology actively supports operations worldwide. For more information, visit (Use the "Apply for this Job" box below). . Follow Shield AI on Linked In , X , Instagram , and You Tube .

Job Description:

Shield AI is seeking a Senior Staff 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. What you'll do:
* 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.

Required qualifications:

* 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 Solid Works) 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.

Preferred qualifications:

* 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…