Staff Mechanical Design Engineer (R3049)

Founded in 2015, Shield AI is a venture-backed defense technology company with the mission of protecting service members and civilians with intelligent, autonomous systems. Its products include Hivemind Enterprise—EdgeOS, Pilot, Commander, and Forge—as well as V-BAT and Sentient Vision Systems (wide-area motion imaging software). With offices in San Diego, Dallas, Washington, D.C., Abu Dhabi (UAE), Kyiv (Ukraine), and Melbourne (Australia), Shield AI’s technology actively supports U.S. and allied operations worldwide.  For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X and Instagram.    

Job Description:

Shield AI is seeking a Staff Mechanical Design Engineer with deep expertise in mechanism design to support the development of our next-generation autonomous UAV platform. In this high-ownership role, you will lead the architecture, design, and development of precision mechanical systems and actuation mechanisms that are critical to mission success.

You will work closely with cross-functional teams to create rugged, lightweight, and manufacturable mechanisms-ranging from landing gear to deployable payload systems-while delivering high performance in dynamic and harsh environments. This is an opportunity to design at the edge of innovation and autonomy, with real-world impact.

What you'll do:

• Architect and design complex electro-mechanical mechanisms, including linkages, actuators, latching systems, deployment arms, and other moving subsystems for autonomous aircraft.
• Own the full design lifecycle: concept creation, detailed CAD, tolerance stack-up, material selection, and drawing release.
• Perform structural and kinematic hand calculations, tolerance analysis, and preliminary FEA to validate mechanism performance.
• Rapidly prototype, iterate, and test mechanism concepts for functionality, durability, and reliability in real-world conditions.
• Work closely with electrical, avionics, flight controls, and propulsion teams to ensure seamless integration of mechanisms into aircraft systems.
• Collaborate with manufacturing teams to ensure designs are DFM-ready, easily assembled, and field serviceable.
• Lead design reviews, cross-functional engineering discussions, and design-for-test planning.
• Mentor junior engineers and support engineering excellence by driving quality, repeatability, and documentation across the team.
• Contribute to pre-production builds, prototype integration, ground testing, and flight validation activities.
• Investigate failures through root cause analysis and implement design improvements for future iterations.

Required qualifications:

• B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or related discipline.
• 7+ years of experience designing mechanical systems, mechanisms, or electro-mechanical subsystems in aerospace, robotics, defense, or advanced hardware domains.
• Strong proficiency in CAD (NX, SolidWorks, or equivalent) with a proven track record of delivering robust, lightweight, and precision-tolerance designs.
• Working knowledge of FEA principles, including structural and thermal analysis for mechanical components.
• Skilled in tolerance stack-ups, GD&T, ANSI Y14.5, and interpreting/creating inspection documentation.
• Experience designing with metallic and composite materials, and familiarity with common aerospace manufacturing processes (machining, composites, 3D printing, sheet metal, etc.).
• Demonstrated ability to work independently and lead projects in cross-functional, fast-paced engineering environments.
• A reputation for high accountability, technical ownership, and being a collaborative and mission-driven teammate.

Preferred qualifications:

• Experience designing mechanical systems for UAVs, aircraft, or robotic systems in defense, aerospace, or commercial sectors.
• Familiarity with actuators (servo, stepper, hydraulic, or electromechanical) and their integration into mechanisms.
• Hands-on experience supporting prototype builds, test plans, and ground/flight testing of mechanical systems.
• Proficiency with failure mode analysis (FMEA), design of experiments (DOE), and root cause investigations.
• Prior experience with Siemens NX or model-based engineering environments.
• Proven ability to thrive in startup, R&D, or defense innovation environments, and to adapt quickly to shifting priorities.

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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.

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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.