Staff Engineer, Mechanical & Actuated Systems (R5293)

Shield; Washington (District of Columbia); On-site; USD 140,000 - 190,000; Full time

Benefits offered by this job

Bonus

Equity

Benefits

Job summary

Shield AI is seeking a Staff Mechanical & Actuated Systems Engineer to advance the design of autonomous UAV platforms. You will develop complex mechanical assemblies, drive concept through production release, and work closely with multi-disciplinary teams to meet performance, schedule and reliability goals.

The role demands strong CAD (NX), extensive FEA and engineering judgment, with hands-on collaboration across design, test and production teams in a fast-paced environment.

Qualifications

• B.S. in Mechanical/Aerospace Engineering is required.
• 7+ years in mechanical or mechanism design.
• Strong CAD skills with NX preferred.
• Kinematic analysis and optimization.
• Structural analysis using hand calculations and FEA.
• FEA: Modal, non-linear and linear, buckling, fatigue.
• GD&T and tolerance stack-ups for mechanical systems.
• Materials selection incl. alloys, heat treatments, and finishes.
• Ability to work independently in fast-paced, cross-functional teams.
• Demonstrated integrity, reliability and teamwork.

Responsibilities

• Design complex electro-mechanical or hydro-mechanical mechanisms for autonomous aircraft.
• Own the full design process: concept, CAD design, analysis, tolerances, materials, and drawing release.
• Perform structural and kinematic calculations and preliminary FEA.
• Prototype, test, and iterate mechanism designs for functionality and reliability.
• Collaborate with electrical, avionics, hydraulics, flight controls, and propulsion teams.
• Support pre-production builds, prototype integration, and ground/flight testing.

Skills

Mechanical design

CAD NX

Kinematic analysis

FEA

GD&T

Materials selection

Independent work

Education

B.S. in Mechanical/Aerospace Engineering

Tools

NX

Job description

Job Description

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 Follow Shield AI onLinkedIn,X,Instagram, andYouTube.

Are you a passionate and innovative product design engineer looking to help develop state-of-the-art AI and aircraft products? Are you eager to make a positive difference in the world? Do you want to work alongside mission driven and values focused teammates? Shield AI is just the place for you!

Staff Mechanical & Actuated Systems Engineer

You will be responsible for contributing to the mechanical design and development of Shield AI's autonomous UAV products. You will help architect mechanical and actuated systems on the X-BAT platform, perform the detailed design of complex mechanical assemblies such as uplocks, doors, flight controls, landing gear, and wing fold, and will use best in class design and analysis tools. You will collaborate closely with internal and/or external partners to prototype, test and release products to production. You will also help ensure product features achieve performance, schedule and reliability goals.

What you'll do:

• Design complex electro-mechanical or hydro-mechanical mechanisms for autonomous aircraft
• Own the full design process: concept, CAD design, analysis, tolerance stack-ups, material selection, and drawing release
• Perform structural and kinematic calculations and preliminary FEA
• Prototype, test, and iterate mechanism designs for functionality and reliability
• Collaborate with electrical, avionics, hydraulics, flight controls, and propulsion teams
• Support pre-production builds, prototype integration, and ground/flight testing

Required qualifications:

• B.S. in Mechanical/Aerospace Engineering
• 7+ years in mechanical or mechanism design
• Strong CAD skills (NX preferred)
• Kinematic analysis and optimization
• Structural analysis utilizing hand calculations and finite element methods
• FEA analysis: Modal, non-linear and linear, buckling, fatigue
• GD&T and tolerance stack-ups for mechanical systems
• Materials selection inclusive of alloys, heat treatments, allowables, and finishes
• Ability to work independently in fast-paced, cross-functional teams
• A demonstrated record of working hard, being trustworthy, holding yourself to high standards, and being kind to others

Preferred qualifications:

• Experience with UAVs, aircraft, or robotic systems
• Familiarity with electro-mechanical actuators
• Proficiency in FMEA, DOE, and root cause analysis
• Hands-on machine shop or mechanic experience (professional or hobby)
• RTCA DO-160, MIL-STD-810, structural, or actuated mechanism testing experience
• Ability to thrive in startup, R&D, or defense innovation environments

#LI-MS1#L4 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.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.