Senior Staff Engineer, Aerostructures Stress Analyst (R5845)

Shield AI is seeking a highly motivated Senior Staff Engineer, Aerostructures Stress Analyst to support the design, development, integration, and fielding of a next-generation autonomous aircraft system.

The ideal candidate is comfortable solving complex problems, taking ownership, working within an accelerated aircraft development environment, and is motivated by getting meaningful capability into the hands of operators quickly.

Responsibilities

• Lead structural analysis efforts for UAV airframes, major substructures, and critical components within a program scope.
• Define and execute finite element modeling approaches, load cases, assumptions, and margin assessments.
• Perform and oversee static, modal, fatigue, vibration, and damage-tolerance analyses.
• Establish sound practices for hand calculations, model validation, and analysis-to-test correlation.
• Drive structural optimization across performance, weight, cost, and manufacturability targets.
• Support structural test strategy, including defining requirements, participating in execution, and correlating results to analysis.
• Review structural analysis deliverables, test reports, and technical documentation for design reviews.
• Mentor and technically guide structural analysts across varying experience levels.
• Partner cross-functionally with design, loads, aero, propulsion, and systems teams to balance structural requirements with overall aircraft performance goals.
• Contribute to evolving analysis methodologies and improving structural standards within the organization.

Required Qualifications

• B.S. in Mechanical Engineering, Aerospace Engineering, or related field.
• 10+ years of experience in structural analysis, aircraft structures, or aerospace systems.
• Strong expertise with FEA tools (ANSYS, NASTRAN, HyperWorks, or similar).
• Advanced proficiency in hand calculations for strength, stability, fatigue, and damage tolerance.
• Significant experience with composite and lightweight aerospace structures.
• Experience supporting structural testing, model correlation, and flight test validation.
• Ability to lead complex technical workstreams and influence design decisions within a program.
• Strong communication skills and experience presenting analysis findings to engineering leadership.
• Ability to get a S//SAR level security clearance desired.

Preferred Qualifications

• Master’s or Ph.D. in Mechanical or Aerospace Engineering.
• Experience serving as a senior technical lead on aircraft or UAV structural programs.
• Hands-on involvement in flight test support and certification efforts.
• Experience contributing to internal analysis standards or best practices.
• Familiarity with CAD, PLM, and enterprise engineering toolchains.

Additional Information

The salary for this position ranges from USD 170,000 to 260,000 per year. The full-time regular employee offer package includes pay within the range listed + Bonus + Benefits + Equity.