Senior Staff Propulsion Design Engineer (R3300) - Shield AI

Job Title: Senior Staff Propulsion Design Engineer (R3300)
Job Location: Dallas Metro Area
Job Listing URL: https://jobs.lever.co/shieldai/6d970989-a9cf-449b-9b95-067bcaccc7d5
Job Description: 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 aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With nine offices and facilities across the U.S., Europe, the Middle East, and the Asia-Pacific, Shield AI’s technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description:
Shield AI is hiring a Senior Staff Propulsion Design Engineer to lead the design, integration, and delivery of propulsion hardware for our next-generation AI-powered UAV. You’ll be responsible for developing the architecture and detailed design of fuel, oil, and bleed air systems—from concept through flight testing.

This position combines deep technical design ownership with high visibility across the engineering organization. You’ll help define design standards, mentor engineers, and ensure that complex propulsion systems meet mission-critical performance, safety, and manufacturability targets.

What you will do in this role:
Lead the design, analysis, and integration of propulsion system components and subsystems.
Drive the development of CAD models, assemblies, and fully dimensioned drawings with GD&T in Siemens NX.
Define propulsion system interfaces, tolerances, and load paths in collaboration with structures, propulsion, and systems teams.
Conduct and review analyses—thermal, structural, and fluid flow—to validate designs and guide decision-making.
Support ground and flight test operations, including build support, anomaly resolution, and test data correlation.
Oversee supplier collaboration, design reviews, and manufacturing readiness for critical components.
Develop and enforce design standards, configuration control, and documentation best practices.
Mentor junior engineers and contribute to the maturation of propulsion design processes and methodologies.
Required qualifications:
B.S. or M.S. in Mechanical, Aerospace, or related engineering discipline.
7–10+ years of experience in mechanical design, preferably with aerospace propulsion or fluid systems.
Advanced proficiency in CAD (NX preferred), GD&T, and complex assembly modeling.
Strong understanding of design-for-manufacturing principles, tolerance analysis, and structural integration.
Hands-on experience supporting prototype builds, resolving non-conformances, and executing design improvements.
Demonstrated experience with analysis tools (e.g., ANSYS, GFSSP, REFPROP, FEA).
Proven ability to lead cross-functional efforts and mentor junior engineers.
U.S. Citizenship or ability to comply with ITAR requirements.
Preferred qualifications:
Background in low-bypass turbofan or UAV propulsion systems.
Experience with thermal, structural, and fluid system design for high-performance aircraft.
Familiarity with supplier management, configuration control, and PLM systems (Teamcenter).
Master’s or Ph.D. in Mechanical or Aerospace Engineering.
Strong communication and leadership skills with a track record of delivering complex aerospace systems from concept to flight.