Senior Mechanical Engineer, Hardware Test; R4325

Senior Mechanical Engineer, Hardware Test (R4325)

Shield AI is pioneering the development of AI‑powered autonomous aircraft for national defense, pushing the boundaries of aerospace innovation. Our next‑generation UAS is a high‑endurance unmanned system designed for deployment in complex, contested environments.

We are seeking a Senior Mechanical Engineer, Hardware Test to lead the design, development, and testing of flight hardware for our next‑generation UAS. This role is instrumental in creating robust, fixed and field‑deployable test systems that enable hardware qualification, environmental testing, stress testing, and sustainment in military environments.

This position requires deep expertise in mechanical design, structural analysis, and aerospace ground systems. You will work closely with engineering, manufacturing, and flight operations teams to develop innovative support solutions that enhance mission effectiveness and operational efficiency.

• Own requirements gathering, design, analysis, and build of mechanical and structural systems.
• Oversee prototyping, testing, and validation of structural designs to meet military and aviation standards.
• Create detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Design structural and electromechanical test stands and fixtures that interface with aircraft, engines, electric motors, circuit boards, and other aeronautical components.
• Conduct structural, thermal, and fatigue analysis to ensure durability and reliability of hardware in field environments.
• Contribute to and attend cross‑functional design reviews. Advocate for design changes that simplify testing processes.
• Work with suppliers and manufacturing partners to ensure cost‑effective production and sustainment of test systems.
• Other duties as assigned.

• B.S. in Mechanical Engineering or related STEM field.
• 5+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Mastery of fundamental engineering concepts, including mechanics, programming, physics, and mathematics.
• Expertise in CAD software (Solid Works, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing aerospace support or civil support equipment.
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
• Ability to work in a fast‑paced, agile development environment with evolving priorities.
• Record of working hard, being a trustworthy teammate, holding yourself and others to high standards, and being kind to others.

• Experience designing UAS or large aerospace‑grade structures.
• Ability to rapidly manufacture designs in a machine shop.
• Experience designing facilities systems and owning large‑scale projects from start to finish.
• Knowledge of hydraulics, structural analysis, and nondestructive (NDE/NDT) aerospace applications.

Salary range: $112,439 – $168,659 per year. Compensation also includes bonus, benefits, and equity. All offers are contingent on a cleared background and possible reference check.

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.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.