Senior Engineer, Structural Analysis (R6027)

Job Description:

Shield AI is seeking a Sr. Structural Analyst to support the analysis and testing of advanced UAVs. In this role, you will work closely with Mechanical Systems, Propulsion, Mechanisms, and other engineering disciplines to ensure the structural integrity of our lightweight, high-performance aircraft. You will contribute to the design, analysis, testing, and optimization of airframe structures and components, ensuring they meet performance, weight, and safety requirements.

This role is ideal for engineers with 5+ years of experience looking to gain expertise in finite element analysis (FEA), composite and metallic materials, and mechanical testing in a fast-paced, high-tech aerospace environment.

What you'll do:

• Assist in building and refining finite element models (FEM) to evaluate the structural performance of UAV components.
• Perform static, modal, fatigue, and vibration analyses to assess stress, deformation, and durability.
• Conduct hand calculations to validate FEA results, ensuring accuracy and structural reliability.
• 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 modeling accuracy and correlate predictions with real-world performance.
• Assist in defining load cases, material properties, and design margins for UAV airframe and mechanical components.
• Document and present structural analysis reports and technical recommendations to engineering teams.
• Collaborate with cross-functional teams to ensure structural requirements align with system performance goals.
• Contribute to the continuous improvement of structural analysis methodologies, tools, and best practices.

Required qualifications:

• 5+ years of experience in structural analysis, finite element modeling, or aircraft loads analysis AND B.S. in Mechanical Engineering, Aerospace Engineering, or related field. Alternatively, 3+ years of experience AND a M.S. in Mechanical or Aerospace Engineering
• Experience with FEA tools (FEMAP, NASTRAN, HyperWorks, ANSYS, Patran, or similar).
• Ability to perform hand calculations for structural strength and stability analysis.
• Knowledge of composite materials and lightweight aerospace structures.
• Familiarity with mechanical testing methods (static, vibration, and/or fatigue).
• Proficiency with data analysis tools (Excel, MATLAB, Python, or similar).
• Strong problem-solving skills, attention to detail, and ability to work in a team environment.
• Ability to obtain a S//SAR level security clearance desired.

Preferred qualifications:

• Experience in aircraft structural design, UAV airframe development, or aerospace testing.
• Hands-on experience with structural testing.
• Exposure to CAD software (NX, Catia, SolidWorks) and PLM tools (Teamcenter or similar).
• Understanding of aerospace industry standards, structural certification processes, and material selection.
• Fatigue and damage tolerance (DaDT) experience including crack initiation and crack growth