Staff Engineer, Mechanical Design - Launch and Recovery Systems (R4571)

Shield AI; Dallas (TX); On-site; USD 137,000 - 205,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Temporary benefits after 60 days

Job summary

Shield AI in Dallas, TX is seeking a Staff Mechanical Design Engineer to lead the design, development, and testing of Ground Support Equipment for our next‑generation UAS. You will create robust, field‑deployable support systems enabling aircraft operations, maintenance, and sustainment in military environments.

Work with engineering, manufacturing, and flight operations to integrate GSE with aircraft systems; perform trade studies, analyses (structural, thermal, fatigue); oversee prototyping,

Qualifications

• 7+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Experience with deployable, transportable, field-ready aerospace support equipment.
• Knowledge of MIL-STD design requirements for aerospace ground support systems.
• Experience with finite element analysis (FEA), thermal analysis, and lifecycle testing.

Responsibilities

• Design and develop mechanical systems for Ground Support Equipment (GSE), including power units, transport structures, launch & recovery systems, and maintenance tools.
• Create detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Conduct structural, thermal, and fatigue analysis to ensure durability and reliability of GSE in field environments.
• Collaborate with cross-functional teams to integrate GSE with aircraft systems and mission operations.
• Perform trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems.
• Oversee prototyping, testing, and validation of GSE designs to meet military and aviation standards.
• Develop technical documentation, test procedures, and support manuals for field operations.
• Work with suppliers and manufacturing partners to ensure cost-effective production and sustainment of GSE.
• Support flight test campaigns by providing engineering support for ground systems and test operations.

Skills

Mechanical design

Aerospace systems

GSE design

Finite element analysis

Tools

SolidWorks

CATIA

NX

Job description

Job Description:

Founded in 2015, 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 and V-BAT and X-BAT aircraft. 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.

Shield AI is pioneering the development of AI-powered autonomous aircraft for national defense, pushing the boundaries of aerospace innovation. Our next gen UAS is a next-generation, high-endurance unmanned system designed for deployment in complex, contested environments.

We are seeking a Staff Mechanical Design Engineer to lead the design, development, and testing of Ground Support Equipment (GSE) for our next gen UAS. This role is instrumental in creating robust, field-deployable support systems that enable aircraft operations, maintenance, and sustainment in military environments.

This position requires deep expertise in mechanical design, structural analysis, and aerospace ground systems. You will work closely with engineering, manufacturing, and flight operations teams to develop innovative support solutions that enhance mission effectiveness and operational efficiency.

What you’ll do:

• Design and develop mechanical systems for Ground Support Equipment (GSE), including power units, transport structures, launch & recovery systems, and maintenance tools.
• Create detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Conduct structural, thermal, and fatigue analysis to ensure durability and reliability of GSE in field environments.
• Collaborate with cross-functional teams to integrate GSE with aircraft systems and mission operations.
• Perform trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems.
• Oversee prototyping, testing, and validation of GSE designs to meet military and aviation standards.
• Develop technical documentation, test procedures, and support manuals for field operations.
• Work with suppliers and manufacturing partners to ensure cost-effective production and sustainment of GSE.
• Support flight test campaigns by providing engineering support for ground systems and test operations.

Required qualifications:

• 7+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Expertise in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing deployable, transportable, and field‑ready aerospace support equipment.
• Knowledge of MIL-STD design requirements for aerospace ground support systems.
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
• Ability to work in a fast‑paced, agile development environment with evolving priorities.

Preferred qualifications:

• Experience designing UAS or military aircraft ground support equipment.
• Knowledge of power distribution, hydraulics, and environmental control systems for aerospace applications.
• Experience with DoD acquisition, sustainment, and field deployment strategies.
• Prior experience supporting military aircraft maintenance and sustainment operations.
• Active Secret or Top Secret clearance (or ability to obtain one).

$136,730 - $205,096 a year

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.