Staff Mechanical Design & Analysis Engineer - Launch & Recovery Vehicle (LRV)

About the role

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.
• Experience evaluating static strength, stiffness, buckling, bolted or welded joints, and fatigue life.
• Experience developing load cases and translating system-level requirements into mechanical designs and analysis criteria.
• Experience designing and analyzing deployable, transportable, and field-ready mechanical systems.
• Knowledge of applicable MIL-STD requirements and their translation into design, analysis, and verification activities for launch and recovery vehicles.
• Experience planning or supporting structural and durability testing, correlating analytical models with test results, and documenting compliance with requirements.
• Ability to work in a fast-paced, agile development environment with evolving priorities.

Preferred qualifications

• Experience designing and analyzing launch and recovery vehicles or associated mechanisms for UAS or military aircraft.
• Experience with nonlinear FEA, contact modeling, transient dynamics, shock and vibration, or multibody dynamics.
• Experience characterizing launch and recovery loads and evaluating their effects on vehicle structures, mechanisms, and aircraft interfaces.
• Experience with thermal analysis and fatigue or lifecycle testing.
• Knowledge of power distribution, hydraulics, actuation, and environmental control systems for aerospace applications.
• Experience with DoD acquisition, sustainment, and field deployment strategies.
• Prior experience supporting military aircraft launch, recovery, maintenance, or sustainment operations.
• Active Secret or Top Secret clearance, or ability to obtain one.

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• 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.