Senior Staff Engineer, Mechanical - Actuated Systems · Shield AI

Fri, 17 Apr 2026 13:06:04 GMT
Engineering

Shield AI · Dallas · $160,000 - $240,000 a year · onsite
Help build the machines that will define the future of autonomous flight. In this role, you will design and deliver high-performance electro-mechanical systems from concept through flight, owning everything from CAD and analysis to prototyping, testing, and production. Working at the intersection of hardware, controls, and propulsion, you’ll solve complex engineering challenges, bring bold ideas to life, and play a direct role in getting cutting-edge aircraft into the air. Responsibilities: - Design complex electro-mechanical mechanisms for autonomous aircraft - Own the full design process: concept, CAD, tolerance analysis, material selection, and drawing release - Perform structural and kinematic calculations and preliminary FEA - Prototype, test, and iterate mechanism designs for functionality and reliability - Collaborate with electrical, avionics, flight controls, and propulsion teams - Mentor junior engineers and promote engineering excellence - Support pre-production builds, prototype integration, and ground/flight testing Required qualifications: - B.S. in Mechanical/Aerospace Engineering - 8+ years in mechanical or mechanism design - Strong CAD skills (NX preferred) - Kinematic analysis and optimization - Structural analysis utilizing hand calculations and finite element methods - FEA analysis: Modal, non-linear and linear, buckling, fatigue - GD&T and tolerance stack-ups for mechanical systems - Materials selection inclusive of alloys, heat treatments, allowables, and finishes - Ability to work independently and lead in fast-paced, cross-functional teams - A demonstrated record of working hard, being trustworthy, holding yourself to high standards, and being kind to others Preferred qualifications: - Experience with UAVs, aircraft, or robotic systems - Familiarity with electro-mechanical actuators - Proficiency in FMEA, DOE, and root cause analysis - Hands-on machine shop or mechanic experience (professional or hobby) - RTCA DO-160, structural, or actuated mechanism testing experience - Ability to thrive in startup, R&D, or defense innovation environments $160,000 - $240,000 a year