Senior Propulsion Design Engineer - Shield AI

Job Title: Senior Propulsion Design Engineer
Job Location: Dallas Metro Area
Job Listing URL: https://jobs.lever.co/shieldai/9c46282e-34fe-42e7-88bd-3dd60eec8840
Job Description: Founded in 2015, Shield AI is a venture-backed defense technology company with the mission of protecting service members and civilians with intelligent systems. Its products include the V-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With offices in San Diego, Dallas, Washington, D.C., Boston, Abu Dhabi (UAE), Kyiv (Ukraine), and Melbourne (Australia), Shield AI’s technology actively supports U.S. and allied operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn,X, YouTubeand Instagram.

Job Description:
We are seeking a Senior Propulsion Design Engineer to support the mechanical design of propulsion system hardware for a low-bypass turbofan-powered UAV. This role covers the full lifecycle of components associated with the engine, oil, fuel, and bleed air systems—from concept and layout through production release and test iteration.

You will contribute to the design and delivery of flight-critical propulsion hardware, ensuring it is well-integrated, manufacturable, and reliable. You’ll collaborate closely with Responsible Engineers, technicians, and production teams to bring architecture to life and support test and flight programs with speed and rigor.

We’re looking for a hands-on engineer with strong CAD skills, solid understanding of manufacturing constraints, and the ability to move quickly without sacrificing quality or detail.

What you will do in this role:
Support the design of propulsion components and subsystems from concept through production release.
Create and maintain CAD models, detailed drawings, and assemblies using Siemens NX with applied GD&T.
Contribute to the development and application of propulsion design standards and team best practices.
Work closely with production, machine shop, and technician teams to support builds and resolve non-conformances.
Assist in developing work instructions, assembly guidance, and documentation for repeatable hardware builds.
Design with a strong awareness of manufacturability, machining limitations, and material and tolerance constraints.
Apply basic engineering analysis and judgment (e.g., hand calcs, ANSYS, FEA, GFSSP, REFPROP) to support sizing and design validation.
Support configuration control, BOM structure, and change processes within Teamcenter or an equivalent PLM.
Participate in design reviews, interface discussions, and problem-solving efforts during hardware development.
Required qualifications:
Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.
5+ years of experience in aerospace mechanical design, preferably with propulsion hardware.
Proficiency in CAD modeling and drawing creation (NX preferred) and sound application of GD&T.
Ability to work effectively with production, technicians, and machine shop teams to resolve design and build issues.
Understanding of design for manufacturing, including stack-up analysis, surface modeling, and fabrication constraints.
Some hands-on experience developing or supporting assembly instructions and resolving build issues.
Familiarity with configuration management and PLM systems such as Teamcenter.
U.S. Citizenship or ability to comply with ITAR requirements.
Preferred qualifications:
Experience with GFSSP, REFPROP, ANSYS, FEA, or similar tools for analysis and validation.
Ability to write Python scripts for design automation, simulation, or data processing.
Proficiency in tolerance stack-up analysis and interface control for complex assemblies.
Knowledge of fastening methods and design for vibration environments.
Familiarity with high-temperature materials and thermally constrained mechanical systems.
Experience designing for internal combustion, turbine, or rocket propulsion systems, particularly in development or test settings.
M.S. in Mechanical Engineering, Aerospace Engineering, or a related discipline.