We are seeking a highly motivated Senior Manufacturing Engineer to lead the development, implementation, and optimization of manufacturing processes for advanced aerospace systems. In this role, you will own one or more aircraft systems throughout the product lifecycle, partnering with Design Engineering, Operations, Quality, Supply Chain, and Program Management to transition products from development into production.
You will play a key role in prototype builds, new product introduction (NPI), production readiness, and production ramp-up while driving improvements in manufacturability, quality, throughput, and cost. This position may support aircraft structures, electrical systems, propulsion, mechanical systems, avionics, final integration, ground support equipment, or other complex aerospace assemblies.
What you'll do:
Lead manufacturing engineering activities for assigned aircraft systems from prototype development through full-rate production.
Develop, implement, and optimize manufacturing processes, production methods, and assembly sequences to improve safety, quality, cost, and throughput.
Design and validate assembly tooling, fixtures, jigs, and manufacturing aids to support efficient and repeatable production.
Develop and maintain work instructions, manufacturing process documentation, standard operating procedures (SOPs), and manufacturing specifications.
Partner with Design Engineering to influence product designs through Design for Manufacturing and Assembly (DFM/DFA) and support engineering change implementation.
Lead prototype builds, production readiness activities, first article inspections, and new product introductions.
Troubleshoot manufacturing issues using structured root cause analysis and implement effective corrective and preventive actions (CAPA).
Drive continuous improvement initiatives focused on manufacturing efficiency, quality, ergonomics, safety, and production capacity.
Collaborate closely with Operations, Quality, Supply Chain, Industrial Engineering, and Program Management to achieve program objectives.
Support supplier manufacturing readiness, process validation, and qualification activities as required.
Utilize CAD software to develop tooling concepts, manufacturing aids, and production support equipment.
Mentor Associate and Manufacturing Engineers while promoting engineering best practices and manufacturing standards.
Support production planning, capacity planning, and manufacturing strategy for future production growth.
Required qualifications:
Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, Industrial Engineering, or a related engineering discipline.
5+ years of manufacturing engineering experience supporting complex aerospace, defense, automotive, robotics, or advanced manufacturing products.
Experience developing manufacturing processes, tooling, and production methods for complex assemblies.
Strong understanding of manufacturing processes such as machining, composites, electrical assemblies, precision mechanical assemblies, or final system integration.
Proficiency with CAD software such as CATIA, Siemens NX, SolidWorks, Creo, or equivalent.
Strong understanding of engineering drawings, GD&T, tolerance analysis, and manufacturing documentation.
Experience supporting prototype builds, production ramp-up, and New Product Introduction (NPI).
Working knowledge of Design for Manufacturing and Assembly (DFM/DFA) principles.
Excellent analytical, troubleshooting, and root cause analysis skills.
Demonstrated ability to lead cross-functional technical initiatives in a fast-paced manufacturing environment.
Preferred qualifications:
Experience supporting military, commercial aerospace, defense, automotive, or advanced manufacturing programs.
Experience with AS9100, ISO 9001, or other regulated manufacturing environments.
Familiarity with Lean Manufacturing, Six Sigma, Value Stream Mapping (VSM), and continuous improvement methodologies.
Experience with ERP, MES, PLM, or digital manufacturing systems.
Experience with automated manufacturing equipment, robotics, or advanced production technologies.
Previous experience mentoring engineers or leading technical projects.
Skills Required
- Bachelor's or Master's degree in Mechanical, Aerospace, Manufacturing Engineering, or related field.
- 5+ years of experience in aircraft manufacturing, assembly, or tooling design.
- Expertise in aircraft structure assembly including fastening, drilling, and tolerance stack-up.
- Proficiency in CAD software (CATIA V5, Siemens NX, or equivalent) for tooling and assembly process design.
- Familiarity with GD&T, metrology techniques, and precision alignment methodologies.
- Experience working with automated assembly systems and advanced manufacturing technologies.
- Knowledge of DFM/DFA (Design for Manufacturability & Assembly) principles.
- Ensure compliance with aerospace industry standards (AS9100, NADCAP, MIL-STD).
- Strong problem-solving skills and ability to work in a fast-paced, high-security environment.
- Prior experience in military aircraft programs (F-35, B-21, F/A-18, F-22, etc.).
- Understanding fabrication, trimming, drilling, fastening, and bonding of composite and metallic aircraft components.
- Understanding of composite materials, layup processes, curing, and bonding techniques.
What the Team is Saying
Shield AI Compensation & Benefits Highlights
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Healthcare Strength — Healthcare coverage is described as excellent, with dental/vision and mental‑health support, and ancillary protections like life and disability appearing in benefit summaries. The breadth and perceived affordability of coverage are highlighted as a standout component of the package.
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Parental & Family Support — Paid parental leave is featured alongside enhanced maternity benefits, fertility and childcare support, and onsite resources such as a Mother’s Room. These elements are positioned as competitive and above the minimal baseline for the company’s stage.
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Equity Value & Accessibility — Equity is granted to all full‑time hires, with RSUs, double‑trigger tax timing, and tools to model scenarios (e.g., through Carta Tax). Communications also reference a transition from options to RSUs, reinforcing access and maturity of ownership programs.
Shield AI Insights
What We Do
At Shield AI, you won't wait years to see your work reach the field. You'll build hardware and software that operates in the real world right now, in the hands of the people who depend on it. Hivemind, our AI pilot, has been flying since 2018. It has flown more than 30 platforms, including an F-16, and it now sits under a U.S. Air Force production contract for Collaborative Combat Aircraft. When you write code or shape a system here, you contribute to technology with a proven flight record and a clear production future. V-BAT flies intelligence, surveillance, and reconnaissance missions with an operational record that stretches from Ukraine to the Indo-Pacific. It delivers eyes where they matter most, in the most demanding conditions on earth. The teams behind it watch their work get tested where the stakes are real. X-BAT takes its first flight this year. It's an AI-piloted fighter that needs no runway, built to operate where traditional aircraft can't. Join now and you help shape a program at its earliest, most formative stage. That's the kind of ground-floor work that defines a career. Do the most impactful work of your life, on problems that matter. Autonomy at this level asks a lot of you. You'll take on problems in perception, planning, and control that few teams anywhere are equipped to solve. You'll work across disciplines, from aerospace and robotics to machine learning and systems engineering, alongside people who hold themselves to an exacting standard and expect the same from you. Our mission is clear: protect service members and civilians with intelligent systems. That purpose runs through every decision, every design review, and every deployment. It's why the work here carries a weight you can feel. Ready to join our mission? Explore our open roles and find where you fit.
Why Work With Us
Founded in 2015 by a former Navy SEAL, Shield AI builds AI pilots and uncrewed aircraft. Veterans aren't an afterthought here, they're at every level. It's why the work carries weight: AI pilots and uncrewed aircraft flying real missions, from Ukraine to the Indo-Pacific, protecting service members and civilians.
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Hybrid Workspace
Employees engage in a combination of remote and on-site work.
