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.
Job Description: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.
What you'll do:
- 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.
Required qualifications:
- 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, SolidWorks, 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.
Preferred qualifications:
- 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 systems, and laboratory equipment.
- Familiarity with aerospace qualification standards such as MIL-STD-810, DO-160, or equivalent.
- Experience designing field-deployable or ruggedized test equipment.
Why this role matters:
The Hardware Test team plays a critical role in ensuring X-BAT hardware performs reliably in demanding operational environments. The test systems and infrastructure you develop will directly support the validation, qualification, and sustainment of mission-critical autonomous aircraft systems.
Skills Required
- 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, SolidWorks, CATIA, or Creo
- 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 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, and data acquisition systems
- Familiarity with aerospace qualification standards such as MIL-STD-810 or DO-160
- Experience designing field-deployable or ruggedized test equipment
What the Team is Saying
Shield AI Compensation & Benefits Highlights
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Healthcare Strength — Company materials describe excellent medical, dental, and vision coverage alongside a mental‑health EAP. Site perks such as an onsite gym in DC and a gym discount in San Diego support a health‑focused offering.
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Retirement Support — Careers materials highlight a 401(k) with company match as part of the standard package. A Total Rewards overview emphasizes retirement features within a broader, transparent compensation view.
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Career-Linked Recognition & Rewards — Compensation for in‑demand technical and senior go‑to‑market roles is described as competitive, with visible engineering ranges and top‑end packages. This points to meaningful upside tied to role, level, and scarce skills.
Shield AI Insights
What We Do
Founded in 2015, Shield AI is a venture-backed deep-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include the V-BAT and X-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With offices and facilities across the U.S., Europe, the Middle East, and the Asia-Pacific, Shield AI’s technology actively supports operations worldwide.
Why Work With Us
What makes Shield AI special is our people. We unlock the power of autonomy, and in the face of overwhelming odds and challenges, we find ways to win and make a difference for our customers. We bring together software, AI, and aerospace engineering disciplines to deploy the most intelligent aviation capabilities in the world.
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Shield AI Offices
Hybrid Workspace
Employees engage in a combination of remote and on-site work.
