Senior Structural Analyst (UAV Airframe)

About the role

Shield AI, a defense-tech company developing autonomous aircraft such as V-BAT and X-BAT, is seeking a Senior Structural Analyst to support the analysis and testing of advanced UAVs. The role works closely with Mechanical Systems, Propulsion, Mechanisms and other engineering disciplines to ensure the structural integrity of lightweight, high-performance aircraft, contributing to the design, analysis, testing and optimization of airframe structures and components.

Key responsibilities

• Build and refine finite element models to evaluate the structural performance of UAV components.
• Perform static, modal, fatigue and vibration analyses to assess stress, deformation and durability.
• Carry out hand calculations to validate FEA results.
• Work with design engineers to optimize airframe structures, balancing weight, strength and manufacturability.
• Support the development of test plans for structural validation, including quasi-static, vibration and shock testing.
• Analyze flight telemetry and structural test data to improve model accuracy and correlate predictions with real-world performance.
• Help define load cases, material properties and design margins for airframe and mechanical components.
• Document and present structural analysis reports and technical recommendations, and collaborate with cross-functional teams.

Required profile

• 5+ years of experience in structural analysis, finite element modeling or aircraft loads analysis, with a B.S. in Mechanical, Aerospace or a related field; alternatively 3+ years of experience and a M.S. in Mechanical or Aerospace Engineering.
• Ability to perform hand calculations for structural strength and stability.
• Knowledge of composite materials and lightweight aerospace structures.
• Familiarity with mechanical testing methods (static, vibration and/or fatigue).
• Ability to obtain a S//SAR level security clearance is desired.

Required skills

• FEA tools such as FEMAP, NASTRAN, HyperWorks, ANSYS, Patran or similar.
• Data analysis tools such as Excel, MATLAB or Python.
• Preferred: aircraft structural design or UAV airframe experience, hands-on structural testing, CAD software (NX, Catia, SolidWorks), PLM tools (Teamcenter), and fatigue and damage tolerance (DaDT) experience.