Principal Airframe & Manufacturing Engineer
Shield AI
Dallas County, TX, USA
Posted on Feb 11, 2025
Founded in 2015, Shield AI is a venture-backed defense technology company with the mission of protecting service members and civilians with intelligent, autonomous systems. Its products include Hivemind Enterprise—EdgeOS, Pilot, Commander, and Forge—as well as V-BAT and Sentient Vision Systems (wide-area motion imaging software). With offices in San Diego, Dallas, Washington, D.C., Abu Dhabi (UAE), Kyiv (Ukraine), and Melbourne (Australia), Shield AI’s technology actively supports U.S. and allied operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X and Instagram.
Job Description:
Shield AI is seeking a Principal Airframe & Manufacturing Engineer to lead the design, development, and production of airframe structures for our next-generation autonomous aircraft.
This is a high-impact role at the forefront of full-scale UAV development, requiring expertise in composite and metallic structural design, advanced manufacturing techniques, and full-aircraft integration. You will work across airframe engineering, material selection, production planning, and manufacturing scalability to deliver a mission-ready, production-efficient UAV platform.
This is an opportunity to work on a brand-new AI-powered aircraft. Your work will directly impact the next generation of autonomous airpower, from early-stage R&D to full-rate production.
What you'll do:
- Lead the design and manufacturing development of advanced airframe structures, ensuring they meet mission, aerodynamic, and durability requirements.
- Develop and optimize composite and metallic structures, including fuselage, wings, and primary load-bearing airframe components.
- Drive the transition from R&D to full-scale production, working closely with manufacturing, suppliers, and fabrication teams to ensure a scalable, high-quality manufacturing process.
- Oversee the integration of propulsion, avionics, and flight control systems within the airframe to ensure a structurally optimized UAV.
- Develop advanced manufacturing processes, including composite layup, bonding, CNC machining, and automated fabrication techniques.
- Ensure compliance with aerospace standards, including MIL-STD, FAA, and DoD regulations, for airframe design and production.
- Conduct structural analysis (FEA), fatigue life assessments, and material stress testing to optimize aircraft performance and longevity.
- Lead airframe prototyping efforts, supporting tooling design, materials testing, and initial flight validation.
- Mentor and provide technical leadership to junior engineers, collaborating across aerospace, manufacturing, and supply chain teams.
Required qualifications:
- Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or a related field.
- 10+ years of experience in airframe structural design, analysis, and production.
- Expertise in composite and metallic materials, bonded structures, and advanced manufacturing methods.
- Hands-on experience in full-aircraft development, from concept to production launch.
- Proficiency in CAD & FEA tools (CATIA, NX, SolidWorks, NASTRAN, Abaqus, ANSYS).
- Strong knowledge of manufacturing processes, including composite layup, bonding, CNC machining, and supplier management.
- Experience with structural testing, fatigue analysis, and load validation for aerospace applications.
- US Citizenship required due to security clearance requirements.
Preferred qualifications:
- 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 aerostructures.
- Experience in scaling aerospace production, including supplier qualification and cost optimization.
#LI-JW2
#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.