Lead Mechanical Engineer, Hardware Test (X-BAT)

Shield; Seattle (WA); Hybrid; USD 150,000 - 230,000; Full time

Job summary

Shield AI seeks a Lead Mechanical Engineer, Hardware Test to spearhead the design and deployment of mechanical test infrastructure for X-BAT hardware. You will build robust test stands, fixtures, and support equipment, while leading a small team and shaping engineering processes in a fast-paced environment.

The ideal candidate brings hands-on mechanical design, fixture development, analysis, and cross-functional coordination across test, electrical, avionics, and manufacturing teams to drive

Qualifications

• B.S. in Mechanical Engineering or related STEM field; advanced degree a plus.
• Proven experience as a senior or lead mechanical engineer developing fixtures, tooling, or test stands for aerospace/defense hardware.
• Experience leading engineers and building high-performance teams, including mentoring and accountability.
• Strong design fundamentals; capable of taking concepts through analysis, detailed design, fabrication, and checkout.
• Proficiency with CAD tools (NX, SolidWorks, CATIA) and releasing drawings for manufacture.
• Familiarity with tolerance stack-up, materials selection, fastener design, load paths, and safe fixture design.
• Hands-on lab/prod environment experience; balance rigor with practical execution.
• Excellent communication across disciplines to translate needs into robust solutions.

Responsibilities

• Lead a team of mechanical engineers designing and maintaining X-BAT hardware test stands and fixtures for subsystem and qualification testing.
• Provide work planning, technical direction, 1:1s, coaching, and performance development for team members.
• Own requirements, concept development, detailed design, and validation of multiple test stands for X-BAT hardware.
• Design fixtures, tooling, and structural support hardware for engineering and production test use.
• Conduct mechanical analyses, including hand calculations and FEA-informed assessments for strength, stiffness, and thermal behavior.
• Apply industry-standard ME practices (GD&T, tolerance analysis, DFM/DFA, design reviews, documentation).
• Collaborate with test, electrical, avionics, manufacturing, and technician teams to integrate safe, repeatable test hardware.
• Support fabrication with internal shops and external vendors; release, procure, assemble, iterate hardware quickly.
• Drive root-cause investigations and implement design improvements; build team processes and documentation.

Skills

Leadership

Aerospace hardware

Mechanical design

CAD tools

Team mentoring

Education

Bachelor's in Mechanical Engineering

Tools

NX

SolidWorks

CATIA

Job description

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.

About Shield AI

Shield AI develops AI-powered autonomy software and aircraft systems that protect service members and civilians by enabling intelligent operations in contested environments. As part of the X-BAT program, you will help develop and validate next-generation autonomous aircraft and mission-critical hardware that must perform reliably in demanding operational conditions.

Job Description

Shield AI is seeking a Lead Mechanical Engineer, Hardware Test to lead the design and development of mechanical test infrastructure that enables rapid, rigorous validation of X-BAT hardware. This role will own the mechanical side of hardware testing, from concept through deployment, by building robust test stands, fixtures, and support equipment for engineering and production-level test activities.

The ideal candidate is a strong technical leader who can manage a small team, establish sound engineering processes, and drive execution in a fast-paced hardware environment. Success in this role requires hands-on experience with mechanical design, fixture development, analysis, fabrication support, and cross-functional coordination in support of complex aerospace hardware test programs.

What you'll do:

• Lead a team of mechanical engineers in designing, building, and maintaining X-BAT hardware test stands and fixtures that support subsystem, integration, and qualification testing.
• Perform core people-lead responsibilities, including work planning, technical direction, regular 1:1s, coaching, feedback, and performance development for the team.
• Own requirements gathering, concept development, detailed design, and validation of multiple test stands used to evaluate X-BAT hardware and supporting subsystems.
• Design fixtures, tooling, structural support hardware, and mechanical systems for engineering and production-level test applications.
• Perform mechanical analyses such as hand calculations and FEA-informed assessments for strength, stiffness, thermal behaviour, durability, and safety.
• Define and apply industry-standard mechanical engineering practices, including GD&T, tolerance analysis, DFM/DFA, design reviews, release documentation, and configuration discipline.
• Partner with test, electrical, avionics, manufacturing, and technician teams to integrate test hardware that is safe, repeatable, maintainable, and efficient to operate.
• Support fabrication and build activities by working closely with internal shops and external vendors to release, procure, assemble, and iterate hardware quickly.
• Drive troubleshooting and root-cause investigations when test hardware or units under test do not perform as expected and implement corrective design improvements.
• Build team processes, documentation habits, and execution rhythms that improve quality, speed, and ownership across the hardware test function.

Required qualifications:

• B.S. in Mechanical Engineering or a related STEM discipline; advanced degree is a plus.
• Proven experience as a senior or lead mechanical engineer developing fixtures, tooling, or test stands for aerospace, defense, robotics, or other complex hardware systems.
• Prior experience leading engineers and building high-performance teams, including mentoring, setting expectations, and driving accountability.
• Strong mechanical design fundamentals with the ability to take concepts through analysis, detailed design, fabrication, assembly, and checkout.
• Proficiency with industry-standard CAD tools such as NX, SolidWorks, or CATIA, and experience releasing drawings for manufacture.
• Familiarity with standard ME practices, including tolerance stack-up, materials selection, fastener design, load path evaluation, and safe machine/fixture design.
• Hands-on experience in lab, prototype, or production environments, with the judgment to balance analytical rigor and practical execution.
• Excellent communication skills and the ability to work across disciplines to translate ambiguous test needs into robust mechanical solutions.
• Demonstrated ownership, strong work ethic, and a track record of improving processes, raising the bar, and delivering results under schedule pressure.

Preferred qualifications:

• Experience with propulsion or engine-related test equipment, high-load structural fixtures, or mechanically complex aerospace ground test systems.
• Familiarity with environmental or qualification testing and the facility interfaces those systems require, such as mounting, cooling, plumbing, or instrumentation accommodations.
• Experience using analysis tools such as ANSYS, Abaqus, or Nastran to support test hardware design decisions.
• Comfort working directly with technicians, machine shops, and test operators to refine designs and improve ease of use in the lab.
• Ability to operate effectively in a fast-moving development program where priorities evolve and rapid iteration is expected.

$150,000 - $230,000 a year

Compensation for this role is based on the position's work location. The salary range shown reflects the listed location and may vary if the position is based in a different geographic market. Actual compensation will also consider factors such as experience, skills, qualifications, and internal equity.

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 toequal 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.