Senior Mechanical Engineer

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. Follow Shield AI on LinkedIn, X, Instagram, and YouTube. 

About Shield AI

Shield AI develops AI-powered autonomy software and aircraft systems that protect service members and civilians by enabling intelligent operations in contested environments. As part of the X-BAT program, you will help develop and validate next-generation autonomous aircraft and mission-critical hardware that must perform reliably in demanding operational conditions.

Job Description:

Shield AI is seeking a Senior Mechanical Engineer to join the Hardware Test organization supporting the X-BAT platform. In this role, you will design, develop, and deploy mechanical test infrastructure used to validate aircraft subsystems, avionics, propulsion components, payloads, power systems, and mission hardware throughout the product lifecycle.

You will work closely with Hardware Test, Design Engineering, Manufacturing, and Reliability teams to develop robust laboratory and field-deployable test systems that accelerate hardware development, improve reliability, and increase confidence in system performance.

This role is ideal for an engineer who enjoys hands-on problem solving, mechanical design, rapid prototyping, and developing creative solutions that enable efficient testing of complex aerospace systems.

What you'll do:

• Design and develop mechanical test fixtures, test stands, environmental test hardware, and integration tooling to support verification and validation activities.
• Create detailed CAD models, engineering drawings, assembly instructions, and manufacturing documentation.
• Support qualification, reliability, environmental, vibration, thermal, and endurance testing of X-BAT hardware.
• Design systems that interface with aircraft structures, avionics, batteries, propulsion systems, payloads, and electromechanical assemblies.
• Perform engineering analyses, including structural, thermal, and fatigue assessments, to ensure safe and reliable operation of test equipment.
• Collaborate with cross-functional teams to define test requirements and develop effective test solutions.
• Support root-cause investigations and failure analysis efforts by developing troubleshooting fixtures and diagnostic hardware.
• Work with machine shops, vendors, and manufacturing partners to fabricate and assemble test equipment.
• Assist with laboratory setup, equipment integration, and maintenance of test infrastructure.
• Contribute to design reviews and advocate for design improvements that simplify testing and increase hardware reliability.
• Support continuous improvement efforts focused on safety, test efficiency, repeatability, and scalability.

Required qualifications:

• B.S. in Mechanical Engineering or related engineering discipline.
• 5+ years of experience designing mechanical systems, test equipment, aerospace hardware, or electromechanical systems.
• Proficiency with CAD software such as NX, SolidWorks, CATIA, Creo, or similar.
• Experience creating engineering drawings and releasing designs for fabrication and assembly.
• Strong understanding of mechanical design fundamentals, materials, manufacturing processes, GD&T, and tolerance analysis.
• Experience designing fixtures, tooling, test stands, or ground support equipment.
• Hands-on experience building, integrating, and troubleshooting mechanical or electromechanical systems.
• Strong analytical and problem-solving skills with the ability to work independently on moderately complex projects.
• Ability to thrive in a fast-paced development environment with evolving priorities.

Preferred qualifications:

• Experience supporting aerospace, defense, robotics, automotive, or autonomous systems programs.
• Experience with finite element analysis (FEA) tools such as ANSYS, Abaqus, or Nastran.
• Familiarity with environmental, vibration, thermal, and durability testing methods.
• Experience working with instrumentation, sensors, data acquisition systems, and laboratory equipment.
• Familiarity with aerospace qualification standards such as MIL-STD-810, DO-160, or equivalent.
• Experience designing field-deployable or ruggedized test equipment.

Why this role matters:

The Hardware Test team plays a critical role in ensuring X-BAT hardware performs reliably in demanding operational environments. The test systems and infrastructure you develop will directly support the validation, qualification, and sustainment of mission-critical autonomous aircraft systems.

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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.