Senior Staff Engineer, Aerostructures Stress Analyst (R5845)

Job Description:

Shield AI is seeking a Senior Staff Structural Analyst to provide advanced technical leadership in the structural analysis and validation of next-generation UAV platforms. In this role, you will serve 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.

This role is ideal for 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 within a program.

What you'll do:

• Lead structural analysis efforts 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 sound 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 defining requirements, participating in execution, and correlating results to analysis.
• Review structural analysis deliverables, test reports, and technical documentation for design reviews.
• Mentor and technically guide structural analysts across varying experience levels.
• Partner cross-functionally with design, loads, aero, propulsion, and systems teams to balance structural requirements with overall aircraft performance goals.
• Contribute to evolving analysis methodologies and improving structural standards within the organization.

Required qualifications:

• B.S. in Mechanical Engineering, Aerospace Engineering, or related field.
• 10+ years of experience in structural analysis, aircraft structures, or aerospace systems.
• Strong expertise with FEA tools (ANSYS, NASTRAN, HyperWorks, or similar).
• Advanced proficiency in hand calculations for strength, stability, fatigue, and damage tolerance.
• 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 within a program.
• Strong communication skills and experience presenting analysis findings to engineering leadership.
• Ability to get a S//SAR level security clearance desired.

Preferred qualifications:

• Master’s or Ph.D. in Mechanical or Aerospace Engineering.
• Experience serving as a senior technical lead on aircraft or UAV structural programs.
• Hands-on involvement in flight test support and certification efforts.
• Experience contributing to internal analysis standards or best practices.
• Familiarity with CAD, PLM, and enterprise engineering toolchains.