Staff Engineer, Mechanical Design - Launch and Recovery Systems (R4572)

Shield AI; Dallas (TX); On-site; USD 136,730 - 205,096; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

A defense technology company in Dallas is seeking a Staff Mechanical Design Engineer to lead the design and development of Ground Support Equipment for next-gen UAS. This role requires over 7 years of experience, strong CAD skills, and knowledge in structural analysis. The successful candidate will work to create field-deployable systems essential for military operations, ensuring the reliability and effectiveness of aircraft support operations. Competitive salary and bonus included.

Qualifications

• Expertise in CAD software for 3-D modeling and design.
• Strong understanding of structural analysis and rugged systems.
• Experience with finite element analysis and lifecycle testing.

Responsibilities

• Design and develop mechanical systems for Ground Support Equipment.
• Conduct analysis to ensure durability and reliability of GSE.
• Collaborate with teams to integrate GSE with aircraft systems.

Skills

Mechanical design

CAD software

Structural analysis

Field-deployable systems

Education

7+ years in aerospace or related field

Tools

SolidWorks

CATIA

NX

Job description

Founded in 2015, Shield AI is a venture‑backed deep‑tech company with the mission of protecting service members and civilians with intelligent systems. Its products include the V‑BAT and X‑BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With offices and facilities across the U.S., Europe, the Middle East, and the 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 3‑D 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

Tempor​ary 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 to equal 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. 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.