Principal Mechanical Engineer, Structural Design (R4444)

Shield AI is a venture-backed deep-tech company focused on protecting service members and civilians with intelligent systems. They are seeking a Principal Structural Design Engineer to lead the design and development of structural components for next-generation autonomous aircraft, ensuring high performance and structural integrity.

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
• 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

Requirements:

• 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