Lead Mechanical Engineer, Hardware Test (X-BAT) (R5271)

About Shield AI

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 Lead Mechanical Engineer, Hardware Test to lead the design and development of mechanical test infrastructure that enables rapid, rigorous validation of X-BAT hardware. This role will own the mechanical side of hardware testing, from concept through deployment, by building robust test stands, fixtures, and support equipment for engineering and production-level test activities.

The ideal candidate is a strong technical leader who can manage a small team, establish sound engineering processes, and drive execution in a fast-paced hardware environment. Success in this role requires hands-on experience with mechanical design, fixture development, analysis, fabrication support, and cross-functional coordination in support of complex aerospace hardware test programs.

What you'll do:

• Lead a team of mechanical engineers in designing, building, and maintaining X-BAT hardware test stands and fixtures that support subsystem, integration, and qualification testing.
• Perform core people-lead responsibilities, including work planning, technical direction, regular 1:1s, coaching, feedback, and performance development for the team.
• Own requirements gathering, concept development, detailed design, and validation of multiple test stands used to evaluate X-BAT hardware and supporting subsystems.
• Design fixtures, tooling, structural support hardware, and mechanical systems for engineering and production-level test applications.
• Perform mechanical analyses such as hand calculations and FEA-informed assessments for strength, stiffness, thermal behavior, durability, and safety.
• Define and apply industry-standard mechanical engineering practices, including GD&T, tolerance analysis, DFM/DFA, design reviews, release documentation, and configuration discipline.
• Partner with test, electrical, avionics, manufacturing, and technician teams to integrate test hardware that is safe, repeatable, maintainable, and efficient to operate.nyc+1
• Support fabrication and build activities by working closely with internal shops and external vendors to release, procure, assemble, and iterate hardware quickly.
• Drive troubleshooting and root-cause investigations when test hardware or units under test do not perform as expected and implement corrective design improvements.
• Build team processes, documentation habits, and execution rhythms that improve quality, speed, and ownership across the hardware test function.

Required qualifications:

• B.S. in Mechanical Engineering or a related STEM discipline; advanced degree is a plus.
• Proven experience as a senior or lead mechanical engineer developing fixtures, tooling, or test stands for aerospace, defense, robotics, or other complex hardware systems.sf+1
• Prior experience leading engineers and building high-performing teams, including mentoring, setting expectations, and driving accountability.
• Strong mechanical design fundamentals with the ability to take concepts through analysis, detailed design, fabrication, assembly, and checkout.
• Proficiency with industry-standard CAD tools such as NX, SolidWorks, or CATIA, and experience releasing drawings for manufacture.
• Familiarity with standard ME practices, including tolerance stack-up, materials selection, fastener design, load path evaluation, and safe machine/fixture design.
• Hands-on experience in lab, prototype, or production environments, with the judgment to balance analytical rigor and practical execution.
• Excellent communication skills and the ability to work across disciplines to translate ambiguous test needs into robust mechanical solutions.
• Demonstrated ownership, strong work ethic, and a track record of improving processes, raising the bar, and delivering results under schedule pressure.

Preferred qualifications:

• Experience with propulsion or engine-related test equipment, high-load structural fixtures, or mechanically complex aerospace ground test systems.
• Familiarity with environmental or qualification testing and the facility interfaces those systems require, such as mounting, cooling, plumbing, or instrumentation accommodations.
• Experience using analysis tools such as ANSYS, Abaqus, or Nastran to support test hardware design decisions.
• Comfort working directly with technicians, machine shops, and test operators to refine designs and improve ease of use in the lab.
• Ability to operate effectively in a fast-moving development program where priorities evolve and rapid iteration is expected.
• Active Top Secret clearance or eligible to achieve, as well as SCI eligible.