Principal Aeronautical Engineer, Airframe & Manufacturing

About Shield AI     

Founded in 2015, Shield AI is a venture-backed defense technology company focused on protecting service members and civilians with intelligent systems. Its flagship autonomy software, Hivemind, powers aircraft, drones, and other platforms, enabling complex missions with high reliability in contested environments. With offices in San Diego, Dallas, Washington, D.C., and internationally, Shield AI’s products actively support U.S. and allied operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn,Twitter, and Instagram.   

Job Description:

Shield AI is seeking a Principal Aeronautical Engineer, Airframe & Manufacturing to lead the design, development, and production of high-performance airframe structures for our next-generation autonomous aircraft platform. This role will require expertise in composite and metallic structural design, manufacturing processes, and full-aircraft integration to develop mission-ready systems optimized for low weight, high durability, and aero structural efficiency.

This is an opportunity to work on a groundbreaking AI-powered aircraft, similar to the V-BAT, and develop full-scale airframes from initial concept to production-ready designs. You will play a key role in ensuring that our aircraft are structurally optimized for flight performance, durability, and rapid manufacturability.

• Lead the structural design and development of airframe components, ensuring they meet aerodynamic, weight, and mission requirements.
• Oversee the design, analysis, and integration of composite and metallic structures, including primary and secondary airframe components.
• Work closely with aerodynamics, propulsion, and avionics engineers to integrate airframe systems seamlessly.
• Develop advanced composite and metallic manufacturing processes, optimizing for weight, durability, and cost.
• Drive structural optimization efforts, ensuring compliance with FAA, DoD, and MIL-STD aerospace standards.
• Provide technical leadership, mentoring junior engineers and working closely with external suppliers and manufacturing partners.
• Conduct finite element analysis (FEA), fatigue life analysis, and structural integrity assessments to enhance aircraft performance.
• Support prototyping, full-scale testing, and production ramp-up efforts to transition from R&D to field deployment.

• Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or a related field.
• 10+ years in airframe structural design, analysis, and manufacturing.
• Deep expertise in composite and metallic materials, airframe assembly, and structural integration.
• Hands-on experience in full-aircraft development, from concept through production.
• Proficiency in CATIA, NX, SolidWorks, and FEA tools (e.g., NASTRAN, Abaqus, ANSYS).
• Strong knowledge of manufacturing processes, including composite layup, bonding, and CNC machining.
• Experience with structural testing, load analysis, and failure analysis.
• US Citizenship required due to security clearance requirements.

• Experience working on high-performance UAVs, military aircraft, or advanced aerospace platforms.
• Knowledge of additive manufacturing, rapid prototyping, and automated composite layup techniques.
• Background in low-observable (stealth) airframe design and advanced aerostructures.

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Total package details for U.S. based positions:

- Regular employee positions: Salary within range listed above + Bonus + Benefits + Equity

- Temporary employee positions: Hourly within range listed above + temporary benefits package (applicable after 60 days

of employment)

- Interns/Military Fellows/Part-time not eligible for bonus, benefits or equity

Total package details for International positions which are roles based outside of the United States (where applicable):

- International premium, hardship differential, cost of living differential, living quarters allowance, foreign service transfer

allowance, equity, international benefits, visa assistance, and relocation assistance.

Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location. All offers are contingent on a cleared background and possible reference check.

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.