Senior Aerostructures Design Engineer (R5158)

Dallas, Texas / San Diego, California

X-BAT Division – X-BAT Engineering - Aerostructures /

Full Time Employee /

On-site

Founded in 2015, Shield AI is a venture-backed defense-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software and V-BAT and X-BAT aircraft. With offices and facilities across the U.S., Europe, the Middle East, and 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 Senior Aerostructures 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 components 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 designs.

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 all stages of the design lifecycle including conceptual development, initial CAD modeling, detailed design, and drawing release.
Perform hand calculations for stress or strain with limited basic FEA analysis, with guidance from senior engineers as needed.
Collaborate closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to support system integration across airframe interfaces.
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, fasteners, tolerancing, and structural optimization.

Required qualifications:

Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related discipline.
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).
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
Ability to get a S//SAR level security clearance desired.

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.
Experience using FEA tools (ANSYS, Abaqus, NASTRAN, or similar) for linear structural analysis

$112,439 - $168,659 a year

#LI-MS

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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.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.

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