# Senior Staff Engineer, Aerostructures Design (R5072)
**Company:** [Shield AI](https://hotfix.jobs/companies/shield-ai)
**Location:** San Diego, CA, Dallas, TX
**Salary:** $160K-$240K
**Experience:** 10+ years
**Skills:** Nx, CATIA, Solidworks, Ansys, Abaqus, Nastran, FEA, GD&T, Dfma, Composites, Stress Analysis, Fatigue Analysis, Mil-Std, Faa Certification
**Posted:** 2026-05-28
> Lead structural design and analysis for next-gen autonomous UAVs, owning CAD, FEA, testing, and cross-functional integration from concept through production. Requires 10+ years aircraft structural design experience and deep expertise in composites, metallic structures, and aerospace standards.
## Job Description
## 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 SolidWorks) 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.

## 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 standards (MIL-STD, ASME Y14.5, FAA FARS) and certification pathways.
- Prior experience in flight vehicle integration, manufacturing liaison, or production support.
- Familiarity with model-based engineering, digital twin development, or configuration management tools.
- Demonstrated experience in failure analysis, design iteration, and test correlation.
- Previous work in startup, R&D, or high-growth defense environments where agility and innovation are key.
**Apply:** https://hotfix.jobs/jobs/senior-staff-engineer-aerostructures-design-r5072-at-shield-ai-2631fef2-35bd-4f37-b0fd-5d36e62454b1
**Canonical:** https://hotfix.jobs/jobs/senior-staff-engineer-aerostructures-design-r5072-at-shield-ai-2631fef2-35bd-4f37-b0fd-5d36e62454b1