# Senior Staff Aerostructures Design Engineer

**Company:** [Shield AI](https://hotfix.jobs/companies/shield-ai)
**Location:** Dallas, TX, San Diego, CA
**Role:** Hardware Engineering
**Salary:** $167k – $250k/yr
**Experience:** 10+ years
**Skills:** aircraft structural design, composites, FEA, CAD, Nx, stress analysis, fatigue analysis, GD&T, dfma, mil-std, ansys, abaqus, nastran
**Posted:** 2026-05-28

> Lead the design, analysis, and development of primary and secondary structural components for next-generation autonomous UAVs. Requires 10+ years aircraft structural design experience, deep composites/metallics expertise, CAD/FEA proficiency, and cross-functional leadership in fast-paced aerospace environments.

## Job Description

## What you'll do

- Lead the design and development of structural components and assemblies for next-gen UAV platform, focusing on primary and secondary aircraft structures.
- Own the structural design lifecycle including concept generation, CAD modeling, detail design, and drawing release.
- Use FEA tools to perform and guide linear and nonlinear structural analysis, stress analysis, and margin assessment.
- Collaborate with aerodynamics, propulsion, avionics, payload, and manufacturing teams for system integration.
- Support material selection focusing on composites, aluminum alloys, and advanced manufacturing.
- Participate in and lead design reviews, architecture discussions, and technical decision-making.
- Oversee structural validation testing at coupon, subcomponent, and full-system levels.
- Guide development of design documentation, analysis reports, interface definitions, and verification plans compliant with MIL-STD, FAA, and internal standards.
- Mentor junior engineers and review work for technical rigor, performance, and manufacturability.
- Collaborate with manufacturing and flight test teams to transition designs to production.
- Identify improvements to design processes, configuration management, and workflows.

## Required qualifications

- Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related discipline.
- 10+ years of experience in aircraft structural design with ownership of components or systems.
- Deep understanding of composite and metallic structures, material behavior, joints, and environmental effects.
- Expertise in CAD (NX, CATIA, or SolidWorks) and FEA tools (ANSYS, Abaqus, NASTRAN, or similar).
- Experience with stress analysis, fatigue analysis, and design optimization.
- Strong knowledge of DFMA, GD&T, tolerance stackups, and structural layout.
- Clear technical communication and experience leading cross-functional efforts.
- Track record of technical excellence, high ownership, and mission-driven mindset.
- Ability to obtain S//SAR level security clearance (desired).

## Preferred qualifications

- M.S. degree in Aerospace or Mechanical Engineering.
- Strong NX CAD skills.
- Experience with Group 3–5 UAV, DoD aircraft, or high-performance aerospace programs.
- Knowledge of aerospace standards (MIL-STD, ASME Y14.5, FAA FARS) and certification.
- Experience in flight vehicle integration, manufacturing liaison, or production support.
- Familiarity with model-based engineering, digital twin, or configuration management tools.
- Experience in failure analysis, design iteration, and test correlation.
- Background in startup, R&D, or high-growth defense environments.

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