Principal Aerostructures Design Engineer (R5163)

Job description

Job responsibilities

• 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.

Job requirements

• Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• 15+ 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.