Principal Mechanical Engineer, Structural Design
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Job Description
Principal Structural Design Engineer developing structural components for next-gen autonomous aircraft. Leading design and development in a fast-paced, high-ownership environment.
Responsibilities:
- 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.
Requirements:
- 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.
Benefits:
- Pay within range listed + Bonus + Benefits + Equity
- Temporary benefits package (applicable after 60 days of employment)
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