Lead Prototype Technician (R

Shield AI; Dallas (TX); On-site; USD 59,000 - 88,000; Full time

Job summary

Shield AI is seeking a Lead Prototype Technician (Level 5) to join our Prototype & New Product Launch team in Dallas. You will build first-of-kind autonomous aircraft, develop manufacturing processes, and drive DFx feedback to production-readiness.

You will transform engineering intent into flight-ready hardware, mentor technicians, and lead cross-functional efforts with Engineering, Manufacturing Engineering, Quality, and Production to ensure scalable prototype builds.

Qualifications

• 10+ years of aerospace manufacturing or prototype experience.
• Extensive aircraft structural assembly experience.
• Advanced composites experience including wet layup and structural repair.
• Experience with engineering development builds.
• Ability to interpret complex engineering drawings and GD&T.
• Strong troubleshooting and problem-solving skills.
• Ability to obtain and maintain a U.S. Security Clearance.

Responsibilities

• Build prototype, developmental, and first article aircraft from engineering concept through flight-ready hardware.
• Perform precision drilling, reaming, countersinking, riveting, fastening, torqueing, safety wiring, structural assembly, and mechanical integration.
• Execute advanced composite manufacturing including wet layup, bonding, trimming, machining, vacuum bagging, structural repairs, finishing, and final assembly.
• Perform complex aircraft modifications and structural repairs.
• Interpret engineering drawings, CAD models, GD&T, specifications, and manufacturing documentation.
• Partner with Design Engineering to provide Design for Manufacturability (DFM) feedback.
• Develop and improve manufacturing work instructions, build sequences, tooling concepts, fixtures, and standardized assembly methods.
• Support engineering validation, qualification builds, and flight test campaigns.
• Fabricate custom brackets, tooling, fixtures, and prototype hardware.
• Mentor Prototype Technicians while establishing best practices and craftsmanship standards.

Skills

Aerospace manufacturing

Prototype manufacturing

Design for Manufacturability (DFM)

GD&T interpretation

Mentoring / leadership

Tools

A&P License

AS9100 experience

Job description

Shield AI is a venture-backed defense-technology 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.

Job Description:

At Shield AI, Prototype Manufacturing is where engineering becomes reality. Our team builds the first aircraft, develops the manufacturing processes, solves complex technical challenges, and establishes the manufacturing foundation that enables scalable production. Every prototype directly influences the future of our products and the capabilities delivered to our customers.

We are seeking an experienced Lead Prototype Technician (Level 5) to join our Prototype & New Product Launch team. This is not a traditional aerospace technician role. You will build first-of-kind autonomous aircraft, develop manufacturing processes, solve challenging technical problems, influence product design through Design for Manufacturability (DFM), and help define how our products transition from prototype to production.

As a Lead Prototype Technician, you will serve as the technical cornerstone of Prototype Manufacturing by transforming engineering intent into flight-ready hardware while driving continuous improvement across manufacturing processes. You will partner closely with Engineering, Manufacturing Engineering, Quality, and Production to ensure our prototype builds are successful today and scalable for tomorrow.

What you’ll do:

• Build prototype, developmental, and first article aircraft from engineering concept through flight-ready hardware.
• Perform precision drilling, reaming, countersinking, riveting, fastening, torqueing, safety wiring, structural assembly, and mechanical integration.
• Execute advanced composite manufacturing including wet layup, bonding, trimming, machining, vacuum bagging, structural repairs, finishing, and final assembly.
• Perform complex aircraft modifications and structural repairs.
• Interpret engineering drawings, CAD models, GD&T, specifications, and manufacturing documentation.
• Partner with Design Engineering to provide Design for Manufacturability (DFM) feedback.
• Develop and improve manufacturing work instructions, build sequences, tooling concepts, fixtures, and standardized assembly methods.
• Support engineering validation, qualification builds, and flight test campaigns.
• Fabricate custom brackets, tooling, fixtures, and prototype hardware.
• Mentor Prototype Technicians while establishing best practices and craftsmanship standards.

Key responsibilities:

• Prototype Manufacturing Excellence
• Design for Manufacturability (DFM)
• Manufacturing Process Development
• Cross Functional Leadership
• Technical Leadership

What success looks like:

• Deliver complex prototype hardware with exceptional quality.
• Solve manufacturing challenges before they become production issues.
• Influence engineering through practical manufacturing expertise.
• Develop repeatable manufacturing processes.
• Mentor technicians and elevate team capability.

Required qualifications:

• 10+ years of aerospace manufacturing or prototype experience.
• Extensive aircraft structural assembly experience.
• Advanced composites experience including wet layup and structural repair.
• Experience with engineering development builds.
• Ability to interpret complex engineering drawings and GD&T.
• Strong troubleshooting and problem-solving skills.
• Ability to obtain and maintain a U.S. Security Clearance.

Preferred qualifications:

• Military aircraft, UAV, eVTOL, or rotorcraft experience.
• Prototype-to-production transition experience.
• AS9100 experience.
• A&P License or equivalent.
• Military aviation maintenance experience.
• Leadership or mentoring experience.

Why join Shield AI:

Unlike traditional aerospace manufacturing, our Prototype Manufacturing team works directly alongside Engineering to create the next generation of autonomous aircraft. You’ll influence design decisions, define manufacturing processes, mentor other technicians, and build technology that protects those who serve.

Shield AI offers competitive compensation, equity participation, comprehensive medical, dental, and vision benefits, 401(k), generous paid time off, professional development opportunities, and the chance to work on some of the world’s most advanced autonomous aircraft systems.

$43 - $64 an hour

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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.

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.