Senior Staff Engineer, Structural Analysis - Ranger

About the role

Shield AI, a defense-tech company developing autonomous aircraft and simulation technologies, is seeking a Senior Staff Structural Analyst for its X-BAT Aerostructures team in Seattle. The role provides advanced technical leadership in the structural analysis and validation of next-generation UAV platforms, acting as a senior subject-matter expert for airframe structures, leading complex analysis efforts, supporting test correlation and ensuring structural integrity across development, flight test and production.

The position suits engineers with 12-15+ years of experience who have led major structural workstreams on aerospace programs and are comfortable owning analysis execution, mentoring engineers and influencing key design tradeoffs.

Key responsibilities

• Lead structural analysis 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 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 requirements definition, execution participation and result correlation.
• Review analysis deliverables, test reports and technical documentation for design reviews.
• Mentor and guide structural analysts across experience levels.
• Partner with design, loads, aero, propulsion and systems teams to balance structural needs with aircraft performance goals.
• Contribute to evolving analysis methodologies and structural standards.

Required profile

• B.S. in Mechanical Engineering, Aerospace Engineering or a related field.
• 10+ years of experience in structural analysis, aircraft structures or aerospace systems.
• 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.
• Strong communication skills and experience presenting analysis findings to engineering leadership.
• S//SAR-level security clearance desired.

Required skills

• FEA tools such as ANSYS, NASTRAN, HyperWorks or similar.
• Advanced hand calculations for strength, stability, fatigue and damage tolerance.

Preferred: Master's or Ph.D. in Mechanical or Aerospace Engineering, prior senior technical lead experience on aircraft or UAV structural programs, hands-on flight test support and certification, and familiarity with CAD, PLM and enterprise engineering toolchains.