Senior Engineer, Mechanical; R5482

Position: Senior Engineer, Mechanical (R5482)
Dallas, TexasV-BAT Division – V-BAT Engineering - Mechanical /Full Time Employee /On-site 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, V-BAT and X-BAT aircraft, and Aechelon simulation and synthetic reality technologies. With offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific, Shield AI’s technology actively supports operations worldwide.

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Job Description:

We are seeking a Senior Mechanical Engineer to design, develop, and release production-ready hardware for the V-BAT aircraft. This individual will own the mechanical design of components and subsystems from concept through production, working closely with electrical, RF, manufacturing, and test teams. The ideal candidate has strong hands-on experience in 3D CAD, 2D production drawings, GD&T, material selection, and design for manufacturing.

This role will help integrate electronics, RF systems, and composite structures into rugged, field-ready airborne platforms. What you'll do:

Design and integrate mechanical components and subsystems for airborne or ruggedized systems, from concept through production.

Create 3D CAD models, assemblies, 2D production drawings, BOMs, and release packages.

Apply GD&T and perform tolerance analyses to ensure fit, function, interchangeability, and inspectability.

Package electronics, including radios, antennas, PCBAs, and harnessing, within assigned subsystems.

Design components and assemblies using metallics, plastics, composites, elastomers, adhesives, and other engineering materials.

Select materials and manufacturing processes based on structural, thermal, environmental, cost, and schedule requirements.

Design for manufacturing processes including CNC machining, additive manufacturing, injection molding, composite fabrication, sheet metal, and bonded assembly.

Collaborate with electrical, RF, manufacturing, quality, supply chain, and test teams to deliver integrated hardware.

Present work in design reviews and perform or support structural, thermal, tolerance, and manufacturability analyses.

Support prototype builds, qualification testing, production integration, troubleshooting, and root-cause investigations.

Ensure designs meet reliability, manufacturability, inspectability, maintainability, and performance requirements. Required qualifications;

Bachelor's degree in Mechanical Engineering or a related engineering field.
5+ years of mechanical design and product-development experience, including ownership of parts or subsystems through production release.

Strong working knowledge of GD&T and ASME Y14.5, including datum selection, position, profile, form and orientation controls, and design for inspection.

Experience creating and releasing detailed 2D production drawings for parts and assemblies.

Proficiency with a production CAD platform such as NX, Creo, CATIA, Solid Works, or Inventor, including part modeling, assemblies, drawing creation, and revision-controlled release.

Experience designing hardware with a range of materials, such as metallics, engineering plastics, composites, elastomers, and adhesives.

Practical design-for-manufacturing experience with multiple processes, such as CNC machining, additive manufacturing, injection molding, composite fabrication, sheet metal, and fastened or bonded assembly.

Working understanding of material selection, tolerance analysis, manufacturing variation, assembly processes, and inspection methods.

Ability to work cross-functionally with manufacturing, quality, electrical engineering, supply chain, technicians,…