Senior Staff Engineer, Aerostructures Stress Analyst (RX) (R5845)

Shield AI is hiring a Senior Staff Engineer, Aerostructures Stress Analyst (RX) (R5845) in Dallas, United States. It pays $170k-$260k a year and Level rates it ; you can apply on Shield AI.

Level's read on this job

Little AI ●○○○ is how Level rates this role: aI is not part of the work.
Tools and skills the posting cites include Ansys, Nastran and Hyperworks.
Level classifies it as a senior role.
Level lists 659 other open roles at Shield AI.

AI in this role

Lead structural analysis efforts for UAV airframes, major substructures, and critical aerospace components.

AnsysNastranHyperworks

stress-analysisfinite-element-modelinguav-structuresaerospace-engineering

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:

We are seeking a highly motivated engineer to support the design, development, integration, and fielding of a next-generation autonomous aircraft system. This position requires a balance of technical rigor, rapid decision-making, and hands-on engineering to efficiently transition concepts into operational capability. The ideal candidate is comfortable solving complex problems, taking ownership, working within an accelerated aircraft development environment, and is motivated by getting meaningful capability into the hands of operators quickly.

What you'll do:

Lead structural analysis efforts for UAV airframes, major substructures, and critical components within a program scope.
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 to balance structural requirements with overall aircraft performance goals.
Contribute to evolving analysis methodologies and improving structural standards within the organization.

Required qualifications:

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

Preferred qualifications:

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.

#LI-MS2 #LE
Full-time regular employee offer package: Pay within range listed + Bonus + Benefits + Equity Temporary employee offer package: Pay within range listed above + temporary benefits package (applicable after 60 days of employment) 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. Military fellows and part-time employees are not eligible for benefits. Please speak to your talent acquisition representative for more information. ### 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.

How we rate this

Senior Staff Engineer, Aerostructures Stress Analyst (RX) (R5845) at Shield AI rates 10 out of 100 for how much of the daily work is AI. That makes it Little AI (AI Level 1 of 4). The level is about AI in the job, not seniority.

Classification

Little AI. AI is not part of the work.

●●●● Builds AI80 to 100
●●●○ Works on AI60 to 79
●●○○ Uses AI40 to 59
●○○○ Little AI0 to 39

Levels come from how often the tools, models and workflows of the role are named in the posting itself. Read the description and count the AI tools, models and workflows it names.

Key facts

Senior Staff Engineer, Aerostructures Stress Analyst (RX) (R5845) is an open job at Shield AI.
Level rates this role AI Level 1 of 4: Little AI.
The listed salary is $170k-$260k a year.
The role is based in Dallas, Texas.
The job was posted on September 24, 2026.
Seniority: senior.
Applications are handled by Shield AI. Apply on Shield AI

Prepare for this job

Built from this posting and from similar jobs on Level.

Skills and AI tools this role asks for

Stress AnalysisFinite Element ModelingUav StructuresAerospace EngineeringAnsysNastranHyperworks

Questions you could be asked

Tell me about a project where stress analysis was part of your work. What did you do?
Tell me about a project where finite element modeling was part of your work. What did you do?
Tell me about a project where uav structures was part of your work. What did you do?
Tell me about a project where aerospace engineering was part of your work. What did you do?
Walk me through how you've used Ansys in your day-to-day work.

Adapt your resume

List these exact terms on your resume: Stress Analysis, Finite Element Modeling, Uav Structures, Aerospace Engineering, and Ansys. An applicant tracking system matches the wording, not the idea.
Attach one line of real, concrete experience to at least one of them. A tool named with nothing behind it rarely survives a human read.

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