Senior Staff Engineer, Structures - Launch Recovery Vehicle (R4765)

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 next-generation, high-endurance unmanned system designed for deployment in complex, contested environments.
We are seeking a Structures Design Engineer to lead the design, development, and testing of a novel launch and recovery system for our next gen UAS. This role is instrumental in creating robust, field-deployable support systems that enable aircraft operations, maintenance, and sustainment in military environments.
This position requires deep expertise in mechanical design, structural analysis, and aerospace ground systems. You will work closely with engineering, manufacturing, and flight operations teams to develop innovative support solutions that enhance mission effectiveness and operational efficiency.

What you'll do:

• Design and develop mechanical systems for a Launch and Recovery System, including power units, transport structures, launch & recovery functions, and maintenance tools.
• Create detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Conduct structural, thermal, and fatigue analysis to ensure durability and reliability of launcher systems in field environments.
• Collaborate with cross-functional teams to integrate launcher with aircraft systems and mission operations.
• Perform trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems.
• Oversee prototyping, testing, and validation of launcher designs to meet military and aviation standards.
• Develop technical documentation, test procedures, and support manuals for field operations.
• Work with suppliers and manufacturing partners to ensure cost-effective production and sustainment of launcher system.
• Support flight test campaigns by providing engineering support for ground and test operations.

Required qualifications:

• 10+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Expertise in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing deployable, transportable, and field-ready aerospace support equipment.
• Knowledge of MIL-STD design requirements for aerospace systems.
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
• Ability to work in a fast-paced, agile development environment with evolving priorities.
• Ability to obtain a S//SAR level security clearance desired.

Preferred qualifications:

• Experience designing UAS or military aircraft ground support equipment.
• Knowledge of power distribution, hydraulics, and environmental control systems for aerospace applications.
• Experience with DoD acquisition, sustainment, and field deployment strategies.
• Prior experience supporting military aircraft maintenance and sustainment operations.
• Active Secret or Top Secret clearance (or ability to obtain one).

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