We are seeking a skilled Mechanical Engineer to join our team, focusing on the design and development of advanced complex opto-mechanical and structural and electronics packing. The ideal candidate will have a strong background in mechanical design, development, analysis, and manufacturing tasks on complex mechanical hardware including precision space structures and mechanisms in a program team environment.
\nThe Mechanical Engineer will develop cutting-edge infrared sensors, design high-precision and complex space opto-mechanical imaging systems, and develop and perform testing to show proof-of-design and/or qualification of new designs. They will utilize first principles physics as a basis for all decisions, build prototypes, analyze failures, and transition successful projects into production.
\nThe successful candidate will have a Bachelor's in mechanical engineering (BSME), or MS with 5 plus years of experience in design, hardware, or integrated product development and testing, and excellent leadership/communication skills. Prior or current experience with spaceflight imaging applications, especially related to optical systems, is highly desirable.
\nThe Mechanical Engineer will work closely with cross-functional teams to design, develop, and test complex mechanical systems, and will be responsible for ensuring that all designs meet industry standards and regulatory requirements.
\nIn addition to designing and developing mechanical systems, the Mechanical Engineer will also be responsible for analyzing and troubleshooting issues with existing systems, and for identifying opportunities for improvement and implementing changes as needed.
\nThe successful candidate will have excellent analytical, troubleshooting, and root-cause analysis skills, and will be able to produce detailed drawings meeting industry standards (e.g., ASME Y14.5 GD&T) and regulatory requirements.
\nThe Mechanical Engineer will also be responsible for driving projects from concept to completion, and for ensuring that all projects are completed on time and within budget.
\nThe successful candidate will have excellent written and verbal skills for documentation, presentations, and collaboration, and will be eligible to obtain and maintain an active U.S. Secret security clearance.
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\nThe successful candidate will have 3+ years of experience in mechanical design/development of high-volume consumer electronic products, good knowledge of plastic, moldflow analysis, injection tooling, injection molding, assembly process and defect analysis, and skillfully use 3D modeling and problem-solving skills.
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\nAs a senior member of the Mechanical Engineering team, you will own the design and development of high-performance structural systems, from clean-sheet concepts to production-ready hardware.
\nKey responsibilities include:
\nLeading the design and development of structural components and assemblies for Shield AI's next-gen UAV platform, with a focus on primary and secondary aircraft structures.
\nOwning the structural design lifecycle including concept generation, CAD modeling, detail design, and drawing release, ensuring high quality and traceability.
\nUsing FEA tools to perform and guide linear and nonlinear structural analysis, stress analysis, and margin assessment under operational loads and edge cases.
\nWorking closely with aerodynamics, propulsion, avionics, payload, and manufacturing teams to ensure seamless system integration across airframe and subsystem interfaces.
\nSupporting and leading efforts in material selection, focusing on composites, aluminum alloys, and advanced manufacturing approaches suited to mission and environment.
\nParticipating in and leading design reviews, architecture discussions, and technical decision-making forums related to structural systems.
\nOverseeing the design and execution of structural validation testing, including coupon-level, subcomponent, and full-system testing.
\nGuiding the development of design documentation, analysis reports, interface definitions, and verification plans in compliance with MIL-STD, FAA, and internal Shield AI standards.
\nMentoring junior engineers and reviewing team members' work for technical rigor, performance, and manufacturability.
\nCollaborating with the manufacturing and flight test teams to transition designs from engineering to production and field deployment.
\nIdentifying opportunities to improve design processes, configuration management, and team workflows for increased engineering velocity and design quality.
\nThis role is ideal for an experienced aerospace mechanical engineer who thrives in fast-paced, high-ownership environments and is passionate about building systems that matter.
\nRequired qualifications include:
\nBachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, or a related discipline.
\n10+ years of experience in aircraft structural design, with demonstrated ownership of components or systems in development, test, or production.
\nDeep understanding of composite and metallic structures, including material behavior, joints, and thermal/environmental effects.
\nExpertise in CAD tools (NX, CATIA, or SolidWorks) and FEA tools (ANSYS, Abaqus, NASTRAN, or similar).
\nExperience conducting or overseeing stress analysis, fatigue analysis, and design optimization.
\nStrong working knowledge of DFMA, GD&T, tolerance stackups, and structural layout principles.
\nClear, concise technical communication skills and experience leading cross-functional engineering efforts.
\nA track record of technical excellence, high ownership, and a mission-driven mindset in challenging engineering environments.
\nPreferred qualifications include:
\nM.S. degree in Aerospace or Mechanical Engineering.
\nStrong NX CAD skills.
\nExperience supporting or leading Group 3–5 UAV, DoD aircraft, or high-performance aerospace vehicle programs.
\nKnowledge of aerospace standards (MIL-STD, ASME Y14.5, FAA FARS) and certification pathways.
\nPrior experience in flight vehicle integration, manufacturing liaison, or production support.
\nFamiliarity with model-based engineering, digital twin development, or configuration management tools.
\nDemonstrated experience in failure analysis, design iteration, and test correlation.
\nPrevious work in startup, R&D, or high-growth defense environments where agility and innovation are key.
\nSalary: $166,632 - $249,948 a year
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\nThis is a multi-level role where the level of responsibility is tailored to the candidate. You'll work across disciplines to ensure structural integrity, manufacturability, and mission-readiness in one of the most advanced autonomous aircraft platforms being built today.
\nResponsibilities:
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