Configuration Design Engineer - Shield AI

Job Title: Configuration Design Engineer
Job Location: Dallas Metro Area
Job Listing URL: https://jobs.lever.co/shieldai/f3fef61e-9d93-45d9-b710-fad3876e1e64
Job Description: 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 an Aircraft Configuration Design Engineer to support the development of next-generation autonomous UAVs. In this role, you will assist in the design, optimization, and integration of aircraft configurations, ensuring that vehicle aerodynamics, structures, propulsion, and mission systems are harmonized for performance, manufacturability, and operational effectiveness.

This position is ideal for a mechanical or aerospace engineer with a passion for cutting-edge aircraft design, multi-disciplinary systems integration, and iterative prototyping in a fast-paced defense technology environment.
What you'll do:
Assist in the conceptual and preliminary design of Shield AI’s UAV platforms, ensuring optimal aerodynamic and structural configurations.
Support aircraft sizing, weight estimation, and trade studies to evaluate different airframe configurations.
Work with multi-disciplinary engineering teams (mechanical, electrical, propulsion, avionics) to ensure seamless system integration.
Develop and refine 3D CAD models of aircraft structures, subsystems, and flight-critical components.
Perform basic aerodynamic and structural analysis using computational tools to assess feasibility and performance impacts.
Participate in design reviews, system trade studies, and prototype development efforts.
Support rapid prototyping and wind tunnel testing of scaled models to validate design concepts.
Assist in requirements development, documentation, and verification planning for aircraft subsystems.
Ensure designs comply with manufacturing feasibility, mission requirements, and aerospace industry standards.
Work closely with manufacturing and production teams to transition designs from concept to prototype and full-scale production.
Required qualifications:
Bachelor’s degree in Aerospace, Mechanical, or Systems Engineering (or related field).
1-5 years of experience in aircraft design, configuration layout, or airframe integration.
Proficiency in CAD modeling (NX, SolidWorks, or similar) for airframe and structural design.
Basic understanding of aircraft aerodynamics, structures, and propulsion system integration.
Ability to perform basic FEA, CFD, or weight & balance assessments.
Strong problem-solving skills, attention to detail, and ability to work in cross-functional teams.
Excellent communication and technical documentation skills.
Preferred qualifications:
Experience with unmanned aerial vehicle (UAV) design or aircraft conceptual design.
Familiarity with aircraft performance modeling, stability & control, and flight dynamics.
Hands-on experience with rapid prototyping, wind tunnel testing, or flight hardware development.
Knowledge of manufacturing techniques, composite materials, and aerospace structural design principles.
Experience working in a fast-paced, high-tech startup or defense environment.