Senior Engineer, Sustaining (R6024)

Shield AI; Dallas, Northern (TX, KY); Hybrid; USD 110,000 - 170,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

Shield AI is seeking a Senior or Staff Mechanical Engineer to lead the resolution of mechanical issues affecting V-BAT production, testing, and fielded aircraft. You will work hands-on to address urgent hardware problems, drive root-cause analyses, and implement permanent corrective actions while prioritizing sustaining engineering over new-product design.

The role requires strong 3D CAD skills, GD&T proficiency, and cross-functional communication to update designs, drawings, and BOMs,

Qualifications

• Bachelor's degree in Mechanical or Aerospace Engineering
• 5+ years for Senior Engineer or 8+ years for Staff Engineer
• Experience supporting production, sustaining engineering, fielded products, or complex hardware troubleshooting
• Ability to lead technical investigations through verified corrective action
• Proficiency with 3D CAD, engineering drawings, GD&T, and manufacturing-focused design
• Strong technical writing and cross-functional communication

Responsibilities

• Lead the resolution of mechanical issues arising from production, testing, fielded aircraft, and customer operations.
• Provide hands-on engineering support during aircraft builds, integration, testing, and troubleshooting.
• Establish immediate containment actions while driving issues through root cause and permanent corrective action.
• Lead structured investigations using fault trees, 5 Whys, failure analysis, and test-based troubleshooting.
• Coordinate investigations across Engineering, Manufacturing, Quality, Supply Chain, Test, and Field Operations.
• Review and disposition deviations, nonconformances, and production questions.
• Determine when issues require changes to designs, drawings, processes, inspections, or supplier controls.
• Update CAD models, drawings, specifications, and bills of material, and drive changes through release and implementation.
• Document investigation results, track recurring issues, and incorporate lessons learned into future designs and processes.

Skills

3D CAD

GD&T

Manufacturing design

Technical writing

Cross-functional communication

Education

Bachelor's degree in Mechanical or Aerospace Engineering

Tools

SolidWorks

Creo/AutoCAD

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-BATaircraft, 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:

We are seeking a Senior or Staff Mechanical Engineer to lead the resolution of mechanical issues affecting V-BAT production, testing, and fielded aircraft. This role will support urgent hardware problems while driving investigations through root cause, permanent corrective action, and verification.

The ideal candidate is comfortable troubleshooting hardware, leading cross-functional investigations, updating designs and drawings, and documenting solutions through release and implementation. This role is focused primarily on sustaining engineering rather than new-product design.

What you'll do:

• Lead the resolution of mechanical issues arising from production, testing, fielded aircraft, and customer operations.
• Provide hands-on engineering support during aircraft builds, integration, testing, and troubleshooting.
• Establish immediate containment actions while driving issues through root cause and permanent corrective action.
• Lead structured investigations using fault trees, 5 Whys, failure analysis, and test-based troubleshooting.
• Coordinate investigations across Engineering, Manufacturing, Quality, Supply Chain, Test, and Field Operations.
• Review and disposition deviations, nonconformances, and production questions.
• Determine when issues require changes to designs, drawings, processes, inspections, or supplier controls.
• Update CAD models, drawings, specifications, and bills of material, and drive changes through release and implementation.
• Document investigation results, track recurring issues, and incorporate lessons learned into future designs and processes.

Required qualifications:

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field.
• 5+ years of relevant experience for Senior Engineer or 8+ years for Staff Engineer.
• Experience supporting production, sustaining engineering, fielded products, or complex hardware troubleshooting.
• Demonstrated ability to lead technical investigations through verified corrective action.
• Proficiency with 3D CAD, engineering drawings, GD&T, and mechanical design for manufacturing.
• Strong technical writing, documentation, and cross-functional communication skills.

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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.

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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.