Shield AI · 3 hours ago
Principal Mechanical Engineer, Structural Design (R4443)
San Diego, TX
Full-time
Onsite
Lead/Staff
10+ years expShield AI is a venture-backed deep-tech company focused on protecting service members and civilians with intelligent systems. They are seeking a Structural Design Engineer to lead the design and development of structural components for next-generation autonomous aircraft, ensuring structural integrity and seamless system integration.
Artificial Intelligence (AI)Autonomous VehiclesDronesMachine LearningNational Security
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
Qualification
Required
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
Preferred
M.S. degree in Aerospace or Mechanical Engineering
NX CAD experience
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
Benefits
Bonus
Benefits
Equity
Temporary benefits package (applicable after 60 days of employment)
Company
Shield AI
Shield AI is a deep-tech company that focuses on developing AI-powered systems to enhance the safety of service members and civilians.
1001-5000 employees
H1B Sponsorship
Shield AI has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (3)
2024 (3)
2021 (1)
Funding
Current Stage
Late StageTotal Funding
$1.31BKey Investors
Hercules CapitalUS Innovative Technology FundSnowpoint Ventures
2025-03-06Series F· $240M
2023-12-29Debt Financing· $200M
2023-10-31Series F· $300M
Leadership Team
Gary Steele
Chief Executive Officer
Brandon Tseng
Co-Founder
Recent News
Morningstar.com
2026-01-19
Dynamic Business
2026-01-19
Washington Technology
2026-01-11
Company data provided by crunchbase