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

• - 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.

• - 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.

• - 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.

#LD

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.

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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 https://shield.ai/.

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