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

Shield; Seattle (WA); On-site; USD 130,000 - 185,000; Full time

Job summary

Shield AI is seeking a Staff Mechanical Design Engineer to lead the design, development, and testing of Ground Support Equipment for its next-generation unmanned aircraft systems. This role focuses on creating robust, field-deployable support systems for operations, maintenance, and sustainment in military environments.

You will collaborate with engineering, manufacturing, and flight operations teams, perform trade studies, validate designs, and develop documentation that ensures compliance with

Qualifications

• 7+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Proficiency in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawings, and layouts.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing deployable, transportable, field-ready aerospace support equipment.
• Knowledge of MIL-STD design requirements for aerospace ground support systems.
• Experience with FEA, thermal analysis, and fatigue/lifecycle testing.
• Ability to work in a fast-paced, agile development environment with evolving priorities.
• Ability to obtain a S//SAR level security clearance desired.

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

CAD software

FEA

Aerospace design

Ground support

Structural analysis

Education

Bachelor's degree in Mechanical Engineering

Tools

SolidWorks

CATIA

NX

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:

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.

• Ability to obtain a S//SAR level security clearance desired.

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).

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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.