Senior Staff Engineer, Aerostructures Stress Analyst (R5845)

Seattle · USD 170,000-260,000 / year · 10+ years experience · Onsite · Posted Sep 24, 2026

At a glance

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.
The role involves serving as a senior subject-matter expert for airframe structures, leading complex analysis efforts, and ensuring structural integrity across development, flight test, and production.

Lead structural analysis efforts for UAV airframes, major substructures, and critical components.
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.
Contribute to evolving analysis methodologies and improving structural standards.

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.

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.
Ability to get a S//SAR level security clearance.