Staff Engineer, Mechanical Design - Launch and Recovery Systems (R4572)

Job Description:

Shield AI is pioneering the development of AI-powered autonomous aircraft for national defense, pushing the boundaries of aerospace innovation. Our next gen UAS is a next-generation, high-endurance unmanned system designed for deployment in complex, contested environments.

We are seeking a Staff Mechanical Design Engineer to lead the design, development, and testing of Ground Support Equipment (GSE) for our next gen UAS. This role is instrumental in creating robust, field-deployable support systems that enable aircraft operations, maintenance, and sustainment in military environments.

This position requires deep expertise in mechanical design, structural analysis, and aerospace ground systems. You will work closely with engineering, manufacturing, and flight operations teams to develop innovative support solutions that enhance mission effectiveness and operational efficiency.

What you'll do:

• Design and develop mechanical systems for Ground Support Equipment (GSE), including power units, transport structures, launch & recovery systems, and maintenance tools.
• Create detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Conduct structural, thermal, and fatigue analysis to ensure durability and reliability of GSE in field environments.
• Collaborate with cross-functional teams to integrate GSE with aircraft systems and mission operations.
• Perform trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems.
• Oversee prototyping, testing, and validation of GSE designs to meet military and aviation standards.
• Develop technical documentation, test procedures, and support manuals for field operations.
• Work with suppliers and manufacturing partners to ensure cost-effective production and sustainment of GSE.
• Support flight test campaigns by providing engineering support for ground systems and test operations.

Required qualifications:

• 7+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Expertise in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing deployable, transportable, and field-ready aerospace support equipment.
• Knowledge of MIL-STD design requirements for aerospace ground support systems.
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
• Ability to work in a fast-paced, agile development environment with evolving priorities.
• Ability to obtain a S//SAR level security clearance desired.

Preferred qualifications:

• Experience designing UAS or military aircraft ground support equipment.
• Knowledge of power distribution, hydraulics, and environmental control systems for aerospace applications.
• Experience with DoD acquisition, sustainment, and field deployment strategies.
• Prior experience supporting military aircraft maintenance and sustainment operations.
• Active Secret or Top Secret clearance (or ability to obtain one).