{"id":1260832,"url":"https://alion.io/job/shield-ai-lead-mechanical-engineer-hardware-test-x-bat","title":"Lead Mechanical Engineer, Hardware Test (X-BAT)","company":{"id":50,"name":"Shield AI","domain":"shield.ai","url":"https://alion.io/company/shield-ai","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Lever","truth_index":{"grade":"B","score":73,"open_postings":90,"ghost_share":0,"stale_share":0.856,"repost_share":0.011,"time_to_fill_p50_days":65,"computed_at":"2026-11-02T06:13:15Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"lead","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Seattle, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":150000,"max":230000,"currency":"USD","period":"year","gross":null,"usd_annual":230000},"salary_estimate":null,"experience_years_min":null,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"GD&T","optional":false},{"name":"Abaqus","optional":true},{"name":"ANSYS","optional":true},{"name":"CATIA","optional":true},{"name":"Nastran","optional":true},{"name":"SolidWorks","optional":true}],"status":"live","first_seen_at":"2026-09-25T16:26:50Z","employer_posted_date":"2026-09-25","last_verified_at":"2026-11-02T17:20:28Z","board_verified":true,"closed_at":null,"days_open":38,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":38},"description":"About Shield AI\n 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.\nJob Description:\nShield 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.\nThe 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.\nWhat you'll do:\nLead a team of mechanical engineers in designing, building, and maintaining X-BAT hardware test stands and fixtures that support subsystem, integration, and qualification testing.\nPerform core people-lead responsibilities, including work planning, technical direction, regular 1:1s, coaching, feedback, and performance development for the team. \nOwn requirements gathering, concept development, detailed design, and validation of multiple test stands used to evaluate X-BAT hardware and supporting subsystems.\nDesign fixtures, tooling, structural support hardware, and mechanical systems for engineering and production-level test applications. \nPerform mechanical analyses such as hand calculations and FEA-informed assessments for strength, stiffness, thermal behavior, durability, and safety.\nDefine and apply industry-standard mechanical engineering practices, including GD&T, tolerance analysis, DFM/DFA, design reviews, release documentation, and configuration discipline.\nPartner with test, electrical, avionics, manufacturing, and technician teams to integrate test hardware that is safe, repeatable, maintainable, and efficient to operate.nyc+1\nSupport fabrication and build activities by working closely with internal shops and external vendors to release, procure, assemble, and iterate hardware quickly.\nDrive troubleshooting and root-cause investigations when test hardware or units under test do not perform as expected and implement corrective design improvements.\nBuild team processes, documentation habits, and execution rhythms that improve quality, speed, and ownership across the hardware test function. \nRequired qualifications:\nB.S. in Mechanical Engineering or a related STEM discipline; advanced degree is a plus. \nProven 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\nPrior experience leading engineers and building high-performing teams, including mentoring, setting expectations, and driving accountability. \nStrong mechanical design fundamentals with the ability to take concepts through analysis, detailed design, fabrication, assembly, and checkout.\nProficiency with industry-standard CAD tools such as NX, SolidWorks, or CATIA, and experience releasing drawings for manufacture.\nFamiliarity with standard ME practices, including tolerance stack-up, materials selection, fastener design, load path evaluation, and safe machine/fixture design.\nHands-on experience in lab, prototype, or production environments, with the judgment to balance analytical rigor and practical execution.\nExcellent communication skills and the ability to work across disciplines to translate ambiguous test needs into robust mechanical solutions. \nDemonstrated ownership, strong work ethic, and a track record of improving processes, raising the bar, and delivering results under schedule pressure.\nPreferred qualifications:\nExperience with propulsion or engine-related test equipment, high-load structural fixtures, or mechanically complex aerospace ground test systems.\nFamiliarity with environmental or qualification testing and the facility interfaces those systems require, such as mounting, cooling, plumbing, or instrumentation accommodations.\nExperience using analysis tools such as ANSYS, Abaqus, or Nastran to support test hardware design decisions.\nComfort working directly with technicians, machine shops, and test operators to refine designs and improve ease of use in the lab.\nAbility to operate effectively in a fast-moving development program where priorities evolve and rapid iteration is 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