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

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

Job summary

Shield AI is seeking a Staff Mechanical Design Engineer to lead design, development, and testing of Ground Support Equipment (GSE) for our next-gen UAS. You will develop robust, field-deployable support systems that enable aircraft operations, maintenance, and sustainment in military environments.

You will work closely with engineering, manufacturing, and flight operations teams to create innovative GSE solutions that enhance mission effectiveness, portability, and ruggedness in demanding

Qualifications

• 7+ years of experience in mechanical design for aerospace or ground support equipment.
• Proficient in SolidWorks, CATIA, NX or equivalent for 3D modeling.
• Experience with FEA, thermal and fatigue testing.
• Knowledge of MIL-STD aerospace ground support requirements.
• Ability to obtain a S//SAR security clearance.
• Experience designing deployable, transportable GSE.
• Strong collaboration with cross-functional teams.

Responsibilities

• Design mechanical systems for Ground Support Equipment (GSE) including power units and transport frames.
• Create CAD drawings, specs for manufacturing.
• Perform structural, thermal, and fatigue analysis.
• Coordinate with engineering, manufacturing, and flight operations.
• Oversee prototyping, testing, and validation to meet standards.
• Develop technical docs, test procedures, and manuals.
• Support suppliers and production for cost-effective sustainment.
• Support flight test campaigns with ground systems.
• Perform trade studies to improve portability and ruggedness.

Skills

Mechanical design

Aerospace systems

3D CAD

Structural analysis

FEA

Tools

SolidWorks

CATIA

NX

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.

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).

$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.

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.