Shield AI
X-BAT Engineering - Aerostructures
SeniorStaffAerostructuresDesignEngineer
Neural analysis suggests this role is
optimal for Senior candidates.
“Senior Staff Aerostructures Design Engineer at Shield AI. Skills: Aerostructures design, Structural analysis, UAV platform development. Lead structural component design. Lead structural assembly design”
Industry & Context.
Failure analysis; Design iteration
Security clearance
What They're Looking For.
Must Have
Bachelor's or Master's degree, 10+ years aircraft structural design, Deep understanding composite/metallic structures, Expertise CAD tools, Expertise FEA tools, Experience stress analysis, Experience fatigue analysis, Experience design optimization, Working knowledge DFMA, Working knowledge GD&T, Working knowledge tolerance stackups, Working knowledge structural layout, Clear technical communication skills, Experience leading cross-functional efforts, Track record technical excellence, Track record high ownership, Track record mission-driven mindset, Ability get S//SAR clearance
Nice to Have
M.S. degree Aerospace/Mechanical Engineering, NX CAD skills, Support/lead Group 3-5 UAV programs, Support/lead DoD aircraft programs, Support/lead high-performance aerospace programs, Knowledge aerospace standards, Knowledge certification pathways, Experience flight vehicle integration, Experience manufacturing liaison, Experience production support, Familiarity model-based engineering, Familiarity digital twin development, Familiarity configuration management tools, Demonstrated failure analysis, Demonstrated design iteration, Demonstrated test correlation, Previous startup experience, Previous R&D experience, Previous high-growth defense experience
What You'll Do.
Lead structural component design
Lead structural assembly design
Own structural design lifecycle
Perform detail design
Perform structural analysis
Guide structural analysis
Perform stress analysis
Perform margin assessment
Work with aerodynamics team
Work with propulsion team
Work with avionics team
Work with payload team
Work with manufacturing teams
Participate design reviews
Participate architecture discussions
Lead architecture discussions
Oversee structural validation testing
Guide structural validation testing
Develop design documentation
Develop analysis reports
Develop interface definitions
Develop verification plans
Mentor junior engineers
Review team members' work
Collaborate manufacturing teams
Collaborate flight test teams
Transition designs to production
Transition designs to field deployment
Identify process improvements
Improve configuration management
Improve team workflows
How You'll Work.
Team & Collaboration
Cross-functional engineering efforts; Manufacturing teams; Flight test teams
Communication Scope
Technical communication
Process & Methodology
Configuration management
Full Job Description
## Description 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 www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube. 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 allo
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