Shield AI is a venture-backed defense-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software, V-BAT and X-BAT aircraft, and Aechelon simulation and synthetic reality technologies. With offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific, Shield AI’s technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description

Shield AI is pioneering the development of AI-powered autonomous aircraft for national defense, pushing the boundaries of aerospace innovation. Our next-gen UAS is a high-endurance unmanned system designed for deployment in complex, contested environments.

We are seeking a Staff Mechanical Design & Analysis Engineer to lead the design, analysis, development, and testing of the Launch & Recovery Vehicle (LRV) for our next-gen UAS. This role combines hands-on mechanical design with rigorous engineering analysis to deliver a robust, field-deployable vehicle that enables aircraft launch, recovery, transport, and associated field operations in military environments.

This position requires deep expertise in mechanical design, structural analysis, and ruggedized mechanical systems. You will own hardware from concept development and analytical substantiation through detailed design, manufacturing, and test validation. Working closely with engineering, manufacturing, and flight operations teams, you will use analysis to inform design decisions and test results to validate and refine predictive models.

What you'll do

Lead mechanical design and engineering analysis of the LRV, including primary structures, mechanisms, aircraft interfaces, transport restraints, and launch and recovery hardware.

Develop concepts, detailed CAD models, engineering drawings, and specifications for manufacturing and assembly.

Define load cases and boundary conditions for launch, recovery, transport, handling, and deployed operations in collaboration with aircraft and systems engineering teams.

Perform hand calculations and finite element analysis (FEA) to evaluate stress, deflection, stability, joint integrity, and structural margins.

Conduct structural, thermal, dynamic, and fatigue analyses, as applicable, to assess LRV performance, durability, and reliability in field environments.

Use analysis-driven trade studies to optimize structural performance, weight, portability, ruggedness, manufacturability, and maintainability.

Select materials, manufacturing processes, fasteners, and joining methods based on performance requirements, analytical results, and operational constraints.

Collaborate with cross-functional teams to integrate the LRV with aircraft systems and mission operations.

Lead prototype development, instrumentation planning, testing, and validation; correlate analytical predictions with test data and resolve discrepancies.

Develop analysis reports, technical documentation, test procedures, and field support manuals.

Work with suppliers and manufacturing partners to resolve design and analysis issues and support cost-effective production and sustainment of the LRV.

Support flight test campaigns by evaluating hardware performance, troubleshooting issues, and implementing design improvements.

Required qualifications

7+ years of experience in mechanical design and structural analysis for aerospace, launch and recovery vehicles, or heavy industrial systems.

Demonstrated ability to own both mechanical design and analytical substantiation of complex hardware from concept through qualification or field deployment.

Expertise in CAD software such as SolidWorks, CATIA, NX, or similar for 3D modeling, drawing creation, and system layout.

Proficiency with FEA tools and engineering hand calculations, including appropriate selection of modeling assumptions, load application, boundary conditions, mesh refinement, and interpretation of results.

Strong background in structural mechanics, load-path development, material selection, and manufacturing processes for ruggedized systems.