Senior Staff Engineer – Aerostructures Stress Analyst

About the role

Shield AI is seeking a senior engineer to lead structural analysis for next‑generation autonomous aircraft. The role blends deep technical rigor with rapid decision‑making to transition concepts into operational capability.

Key responsibilities

• Lead structural analysis of UAV airframes, substructures, and critical components, defining FEA models, load cases, and margin assessments.
• Perform static, modal, fatigue, vibration, and damage‑tolerance analyses and validate models against test data.
• Drive structural optimization for performance, weight, cost, and manufacturability while supporting test strategy and execution.
• Mentor junior analysts and collaborate cross‑functionally with design, loads, aero, propulsion, and systems teams.

Required profile

• B.S. in Mechanical, Aerospace Engineering or related field with 10+ years of experience in aircraft structural analysis.
• Proven ability to lead complex technical workstreams and influence design decisions.
• Strong communication skills and experience presenting findings to engineering leadership.
• Ability to obtain a S//SAR level security clearance (desired).

Required skills

• Proficiency with FEA tools such as ANSYS, NASTRAN, HyperWorks.
• Advanced hand‑calculation expertise for strength, stability, fatigue, and damage tolerance.
• Experience with composite and lightweight aerospace structures.
• Familiarity with CAD, PLM, and enterprise engineering toolchains.