Staff Engineer, Tool Design (R4967)

Shield AI; Dallas (TX); On-site; USD 120,000 - 190,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

A leading aerospace technology firm seeks a Senior Tool Design Engineer in Dallas, Texas, with over 7 years of experience in tooling and mechanical design. This role involves managing tooling throughout its lifecycle, including design and fabrication. Candidates should possess a Bachelor’s degree in Mechanical or Aerospace engineering and have knowledge of GD&T, CATIA, and FEA tools. The position offers a competitive salary range of $120,000 to $190,000 annually and includes a bonus and benefits.

Qualifications

• 7+ years of experience in tooling design, mechanical design or manufacturing engineering.
• Experience in prototype manufacturing in a startup or rapid-growth environment.
• Strong understanding of manufacturing processes including machining, composites, avionics and/or assembly.

Responsibilities

• Translate GD&T and key characteristics into tooling requirements.
• Design assembly jigs, molds, and fixtures using CATIA/NX/SolidWorks.
• Conduct FEA and hand calculations to confirm safety factors and ergonomics.
• Generate complete Tool Design Packages including 3D models and 2D drawings.
• Manage tool fabrication and support shop-floor prove-out.

Skills

CATIA

NX

SolidWorks

FEA tools

GD&T

Metrology fundamentals

Supplier manufacturing processes

Education

Bachelor’s degree in Mechanical, Aerospace, Industrial, Mechatronics or related field

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 nine 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:

The Senior Tool Design Engineer brings 7+ years of experience developing production tooling for complex aerospace systems. This role owns tooling throughout its lifecycle (concept, design, analysis, release, fabrication, and prove‑out) ensuring safe, repeatable, first‑time‑right assembly. You will work cross‑functionally with Manufacturing, Quality, and Safety to deliver robust tooling that supports pilot builds through rate production.

What you’ll do:

• Translate GD&T, key characteristics, and CTQs into tooling requirements (datums, locators, clamps, tolerances, ergonomics, ESD/FOD controls).
• Design assembly jigs, drill/bond fixtures, composites molds & trim fixtures, go/no‑go gauges, lifting/handling carts, and protective tooling using CATIA/NX/SolidWorks.
• Conduct FEA and hand calculations to confirm stiffness, clamp loads, safety factors, and ergonomics.
• Generate complete Tool Design Packages including 3D models, 2D drawings with GD&T, BOM, torque/fastener specs, materials/finishes, lifting points, and safety labeling.
• Lead design reviews with ME, Quality, Safety, and Launch teams; perform human‑factors evaluations.
• Manage tool fabrication, oversee NCR/ECR resolution, and support shop‑floor prove‑out.
• Develop Tool Setup & Care Instructions, PM plans, and inspection checklists.
• Support First Article activities including CMM/laser‑tracker alignment, gage strategy, and dimensional validation.

Tools & Skills

• CATIA / NX / SolidWorks, 3DEXPERIENCE / Teamcenter, FEA tools, GD&T, metrology fundamentals, supplier manufacturing processes.

Required qualifications:

• 7+ years of experience in tooling design, mechanical design, or manufacturing engineering.
• Bachelor’s degree in Mechanical, Aerospace, Industrial, Mechatronics, or related engineering field.
• Experience in prototype manufacturing in a startup or rapid‑growth environment.
• Strong understanding of manufacturing processes, including machining, composites, avionics and/or assembly.
• Demonstrated ability to work in a fast‑paced, high‑pressure environment and adapt to changing priorities.

Preferred qualifications:

• Knowledge of quality standards, such as AS9100 or ISO 9001.
• Familiarity with advanced manufacturing technologies, such as additive manufacturing or automation systems.
• Strong project management skills, including experience managing multiple priorities and deadlines.

$120,000 - $190,000 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 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.