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Agent guide: [/agents.md](https://www.wearedevelopers.com/agents.md). --- # Senior Staff Aerostructures Design Engineer (R5161) - **Company:** Shield AI - **Location:** San Diego, CA, United States - **Experience:** Expert - **Contract:** Temporary contract - **Skills:** Computer-Aided Design, Abaqus, Artificial Intelligence, Computer Aided Three-Dimensional Interactive Application (CATIA), Configuration Management, SolidWorks (CAD), Nastran (Computer-Aided Design Software), System Testing, Systems Integration, Siemens NX, Infrastructure Automation Frameworks, Ansys - **Published:** July 24, 2026 - **Apply:** https://www.clearancejobs.com/jobs/9054978/senior-staff-aerostructures-design-engineer-r5161 ## About the Role * 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. * Ability to get a S//SAR level security clearance desired. * 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. ## Description Shield AI is seeking a Senior Staff Aerostructures Design Engineer to play a critical role in the development of structural components for our next-generation autonomous aircraft. As a senior member of the Mechanical Engineering team, you will own the design and development of high-performance structural systems, from clean-sheet concepts to production-ready hardware. You'll work across disciplines to ensure structural integrity, manufacturability, and mission-readiness in one of the most advanced autonomous aircraft platforms being built today. This role is ideal for an experienced aerospace mechanical engineer who thrives in fast-paced, high-ownership environments and is passionate about building systems that matter. * 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. ## Related Videos - [Crew Management System for Airlines: Plan duties for pilots & flight attendants worldwide](https://www.wearedevelopers.com/videos/1444-crew-management-system-for-airlines-plan-duties-for-pilots-flight-attendants-worldwide) - [Cloud Vendor Lock-In - Is it just a new version of the Database Abstraction Layers?](https://www.wearedevelopers.com/videos/1185-cloud-vendor-lock-in-is-it-just-a-new-version-of-the-database-abstraction-layers) - [Remote Driving on Plant Grounds with State-of-the-Art Cloud Technologies](https://www.wearedevelopers.com/videos/251-remote-driving-on-plant-grounds-with-state-of-the-art-cloud-technologies) - [Colorful quantum randomness](https://www.wearedevelopers.com/videos/100257-colorful-quantum-randomness) - [C# 13 Unleashed: Live Demos of my Top 10 Cutting-Edge Features!](https://www.wearedevelopers.com/videos/1225-c-13-unleashed-live-demos-of-my-top-10-cutting-edge-features) - [Robots are coming into the wild! 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