Staff Engineer, Tool Design (R4967)

Shieldai; Seattle (WA); On-site; USD 120,000 - 170,000; Full time

Job summary

Shield AI is seeking a Senior Tool Design Engineer with 7+ years of experience to own tooling for complex aerospace assemblies from concept through prove-out. You will collaborate with Manufacturing, Quality and Safety to deliver robust tooling for pilot builds through rate production, translating GD&T and CTQs into precise tooling requirements.

You will design jigs, fixtures, gauges, and protective tooling using CATIA/NX/SolidWorks, perform FEA as needed, and lead cross-functional design

Qualifications

• 7+ years of tooling design experience in aerospace or related field.
• Bachelor’s degree in Mechanical, Aerospace, Industrial, Mechatronics, or related engineering field.
• Experience with tooling for complex assemblies and lifecycle ownership.
• Familiarity with AS9100 or ISO 9001 quality standards.
• Experience in prototype manufacturing in startup or rapid-growth environments.

Responsibilities

• Translate GD&T, datums, locators, clamps, tolerances and ergonomics into tooling requirements.
• Design assembly jigs, fixtures, gauges, and protective tooling using CATIA/NX/SolidWorks.
• Conduct FEA and hand calculations to verify stiffness and safety factors.
• Generate Tool Design Packages with 3D models, 2D drawings, BOM, and specs.
• Lead design reviews with ME, Quality, Safety, and Launch teams.
• Manage tool fabrication, NCR/ECR resolution, and shop-floor prove-out.
• Develop Tool Setup Instructions, PM plans, and inspection checklists.
• Support First Article activities including CMM/laser-tracker alignment.

Skills

Tool design

Mechanical design

Project management

Manufacturing engineering

GD&T

Quality standards knowledge

Education

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

Tools

CATIA/NX/SolidWorks

3DEXPERIENCE/Teamcenter

FEA tools

GD&T

Metrology fundamentals

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:

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.

• 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.
• 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
• 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.

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.