Senior Staff Engineer – Structures for Launch Recovery Vehicle

About the role

Shield AI is developing AI‑powered autonomous aircraft for national defense and seeks a senior engineer to lead the design of a novel launch and recovery system for its next‑generation unmanned aircraft. The role focuses on creating robust, field‑deployable support structures that enable aircraft operations, maintenance, and sustainment in contested environments.

Key responsibilities

• Design and develop mechanical systems for the Launch and Recovery System, including power units, transport structures, launch/recovery mechanisms, and maintenance tools.
• Create detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Conduct structural, thermal, and fatigue analyses to ensure durability and reliability in field conditions.
• Collaborate with cross‑functional teams to integrate the launcher with aircraft systems and mission operations.
• Perform trade studies and system optimization to improve portability, ruggedness, and maintainability.
• Oversee prototyping, testing, and validation to meet military and aviation standards.
• Develop technical documentation, test procedures, and support manuals for field use.
• Work with suppliers and manufacturing partners to ensure cost‑effective production and sustainment.
• Provide engineering support for flight test campaigns and ground operations.

Required profile

• 10+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Expertise in CAD software such as SolidWorks, CATIA, or NX for 3D modeling and drawing creation.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing deployable, transportable, field‑ready aerospace support equipment.
• Knowledge of MIL‑STD design requirements for aerospace systems.
• Proficiency with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
• Ability to thrive in a fast‑paced, agile development environment.
• Ability to obtain a S//SAR level security clearance (desired).

Required skills

• SolidWorks
• CATIA
• NX
• Finite Element Analysis (FEA)
• Thermal analysis
• Fatigue testing
• MIL‑STD compliance
• Power distribution systems
• Hydraulics
• Environmental control systems