Staff Engineer, Propulsion Systems Advance Manufacturing (R5185)

Shield; Washington (District of Columbia); On-site; USD 120,000 - 165,000; Full time

Benefits offered by this job

Bonus

Equity

Benefits

Job summary

Shield AI seeks a Staff Propulsion Systems Manufacturing Engineer to lead manufacturing engineering for propulsion and fluid systems in aerospace/defense hardware. You will drive production-ready processes, toolings, and work flows, partnering with design to improve manufacturability and reliability, while mentoring junior engineers.

The role emphasizes root-cause analysis and DFM/DFA implementation. Ideal candidates bring 7+ years in propulsion/fluids manufacturing, a relevant bachelor’s

Qualifications

• 7+ years of manufacturing engineering experience supporting propulsion or fluid systems.
• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Manufacturing.
• Prototype manufacturing experience in startup or rapid-growth environment.
• Experience with engine assembly, fuel/oil systems, propulsion hardware.
• Ability to work in a fast-paced, high-pressure environment and adapt to changing priorities.
• Knowledge of manufacturing process development and production scaling.
• Strong understanding of DFM/DFA principles and root-cause methodologies.

Responsibilities

• Lead manufacturing engineering support for propulsion and fluid system assemblies.
• Develop and optimize processes, tooling, work instructions, production flows.
• Collaborate with design to improve manufacturability, reliability, testability, producibility.
• Drive root cause investigations and corrective actions for propulsion issues.
• Develop work instructions, quality standards, inspection methods.
• Support supplier qualification, process validation, and production readiness reviews.
• Lead DFM/DFA reviews and transition products to manufacturing.
• Support system integration, validation, and troubleshooting activities.
• Define manufacturing standards, process controls, and acceptance criteria.
• Support failure analysis and reliability improvement initiatives.
• Collaborate with production, quality, supply chain, and test engineering teams.
• Mentor junior manufacturing engineers.

Skills

Propulsion manufacturing

Fluid systems

DFM/DFA principles

Root cause analysis

Project management

Lean manufacturing

Adaptability to fast pace

Education

Bachelor’s degree in Mechanical Engineering

Tools

3DEXPERIENCE / Teamcenter (PLM) systems

MES & QMS systems

CAD software

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 on LinkedIn, X, Instagram, and YouTube.

We are seeking a Staff Propulsion Systems Manufacturing Engineer to lead manufacturing engineering activities for advanced propulsion and fluid systems used in aerospace and defense applications. This role supports engine integration, fuel systems, oil systems, pumps, and related propulsion hardware from development through production. The ideal candidate has deep experience with propulsion-related manufacturing processes, fluid systems integration, and production support for mission-critical hardware.

What you'll do:

• Lead manufacturing engineering support for propulsion and fluid system assemblies
• Develop and optimize manufacturing processes, tooling, work instructions, and production flows for: Engines and propulsion systems Fuel systems and fuel tanks Oil and lubrication systems Pumps and fluid control hardware Aerospace vector and thrust systems
• Partner with design engineering to improve manufacturability, reliability, testability, and producibility
• Drive root cause investigations and corrective actions for propulsion manufacturing issues
• Develop work instructions, quality standards, and inspection methods
• Support supplier qualification, process validation, and production readiness reviews
• Lead DFM/DFA reviews and transition new products into manufacturing
• Support system integration, validation, and troubleshooting activities
• Define manufacturing standards, process controls, and acceptance criteria
• Support failure analysis and reliability improvement initiatives
• Collaborate with production, quality, supply chain, and test engineering teams
• Mentor junior manufacturing engineers

Tools & skills:

• MES & QMS systems
• 3DEXPERIENCE / Teamcenter (PLM) systems
• Supplier manufacturing processes
• 5S/visual management
• Standard Operating Procedures (SOPs)

Required qualifications:

• 7+ years of manufacturing engineering experience supporting propulsion or fluid systems
• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Manufacturing
• Experience in prototype manufacturing in a startup or rapid-growth environment.
• Experience with: Engine assembly and integration Fuel and oil systems Precision fluid system manufacturing Aerospace propulsion hardware
• Demonstrated ability to work in a fast-paced, high-pressure environment and adapt to changing priorities.
• Knowledge of manufacturing process development and production scaling
• Strong understanding of DFM/DFA principles
• Experience with root cause analysis and corrective action methodologies

Preferred qualifications:

• Aerospace or defense industry experience
• Experience supporting turbine, piston, hybrid-electric, or UAV propulsion systems
• Knowledge of pressure systems, leak testing, and fluid handling
• Familiarity with lean manufacturing and production optimization
• Experience with ERP/MES systems and manufacturing data analysis
• Strong project management skills, including experience managing multiple priorities and deadlines
• Knowledge of quality standards, such as AS9100 or ISO 9001
• Proficiency in CAD software

#LI-JM1#LD

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 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 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.