Sr. Staff Mechanical Engineer - BlueSky (R5825)

Aircraft Leadership Full Time Employee Shield AI is a venture-backed defense-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software, V-BAT and X-BAT aircraft, and Aechelon simulation and synthetic reality technologies. With offices and facilities across the U.S., Europe, the Middle East, and 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. Help design and deliver the mechanical systems that power advanced aerospace blue-sky platforms from concept to real-world operation. In this role, you will own hardware development across the full product lifecycle—working hands-on in CAD, analysis, and testing—while collaborating with cross-functional teams to build reliable, high-performance systems. Operating in a fast-paced environment, you’ll turn complex challenges into practical solutions and play a key role in bringing mission-ready technology to life. Directly contribute to the design, analysis, and integration of mechanical systems and subsystems, including avionics packaging, harnessing and connector selection, and structures. Own mechanical engineering deliverables across the product lifecycle - from early concept and prototyping through test, production, and field support - with a bias toward execution and delivery. Partner closely with Engineering functions, Manufacturing, Supply Chain, and Quality to ensure designs are buildable, testable, and reliable in real-world environments. Provide hands-on technical support during testing, demos, and field operations; rapidly troubleshoot and implement design fixes under tight timelines. Required qualifications: Bachelor’s degree in Mechanical Engineering, or closely related field from an accredited institution. 5-6 years of hands-on mechanical design experience in aerospace, ground support equipment, or related ruggedized hardware systems. Proficiency in 3D CAD software (SolidWorks, NX, CATIA, or similar) with demonstrated ability to create detailed drawings, assemblies, and GD&T-compliant documentation Strong foundation in structural design, material selection, and manufacturing processes. Experience performing engineering calculations (stress, thermal, tolerance stack-up, fatigue, FEA as applicable) to validate design integrity Cross-functional collaboration experience with Manufacturing, Quality, Supply Chain, and Program Management. Preferred qualifications: Root cause analysis and structured problem-solving capability to resolve mechanical failures. Familiarity with industry standards (ASME, ISO, ASTM, or industry-specific regulatory requirements). Familiarity with MIL-STD requirements and environmental qualification testing. Familiarity to power distribution, hydraulics, or aerospace support systems. Experience working with external suppliers or contract manufacturers.