S
Shieldai3mo ago
USD 190000–290000/yr

Principal Aerostructures Design Engineer (R4721)

United StatesUnited StatesRemoteFull Time Employeelead
EngineeringOtherDesign EngineerTrades & Skilled LaborAerostructures Design Engineer
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Quick Summary

Overview

Founded in 2015, Shield AI is a venture-backed deep-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include the V-BAT and X-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines.

Technical Tools
EngineeringOtherDesign EngineerTrades & Skilled LaborAerostructures Design Engineer
Founded in 2015, Shield AI is a venture-backed deep-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include the V-BAT and X-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With offices and facilities across the U.S., Europe, the Middle East, and the 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 Principal Structural 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.
  • 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.
  • 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.
  • 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.

    • Location & Eligibility

    Where is the job
    United States
    Remote within one country
    Who can apply
    Open to applicants worldwide
    Listed under
    United States

    Listing Details

    Posted
    January 24, 2026
    First seen
    March 25, 2026
    Last seen
    May 12, 2026

    Posting Health

    Days active
    48
    Repost count
    0
    Trust Level
    51%
    Scored at
    May 13, 2026

    Signal breakdown

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    Principal Aerostructures Design Engineer (R4721)USD 190000–290000
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