Senior Mechanical Engineer, Structural Design (r4443)

Senior Structural Design Engineer

Shield AI is seeking a Senior Structural Design Engineer to support the development of structural components for our next-generation autonomous aircraft. As a key contributor on the Mechanical Engineering team, you will design and develop high-performance structural hardware from concept through production release.

You'll work cross-functionally to ensure structural integrity, manufacturability, and system integration across one of the most advanced autonomous aircraft platforms being built today. This role is ideal for an aerospace mechanical engineer who thrives in hands-on design environments and is eager to take increasing ownership of flight-critical hardware.

What you'll do:

• Design and develop structural components and assemblies for Shield AI's next-generation UAV platform, supporting both primary and secondary aircraft structures.
• Execute the structural design lifecycle including concept development, CAD modeling, detail design, and drawing release.
• Perform linear structural and stress analysis using FEA tools under defined loading conditions, with guidance from senior engineers as needed.
• Collaborate closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to support system integration across airframe interfaces.
• Contribute to material selection decisions, including composites and metallic structures, aligned to performance and manufacturability goals.
• Support structural validation efforts including coupon testing, subcomponent testing, and system-level verification.
• Generate high-quality design documentation, drawings, interface definitions, and analysis reports in compliance with aerospace standards.
• Partner with manufacturing and flight test teams to resolve build issues and support hardware through test and deployment.
• Participate in design reviews and technical discussions, presenting work clearly and incorporating feedback effectively.
• Continuously improve personal technical depth in structural layout, joints, tolerancing, and structural optimization.

Required qualifications:

• Bachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, or related discipline.
• 4–5+ 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).
• Experience using FEA tools (ANSYS, Abaqus, NASTRAN, or similar) for linear structural analysis.
• 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 qualifications:

• 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.

$112,439 - $168,659 a year

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.

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.