Senior Mechanical Engineer, Hardware Test - X-BAT; R5271

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.

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.

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.

• 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.

• 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, Solid Works, 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.

• 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…