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Shield AI, a venture-backed defense-tech company, is seeking a Principal Propulsion Engineer to own the design of propulsion components and subsystems from concept through production release. You will develop and maintain high-quality CAD models, detailed drawings, and assemblies using Siemens NX with fully applied GD&T. You'll write and enforce propulsion design standards, contribute to company-wide design best practices, and collaborate closely with the machine shop, production team, and technicians to support builds, resolve non-conformances, and drive iterative improvements.
Key responsibilities include developing initial work instructions and assembly guidance for repeatability and scalability, ensuring designs are practical, manufacturable, and cost-effective with strong understanding of machining, tolerances, materials, and assembly workflows. You will apply engineering analysis and judgment (hand calculations, GFSSP, ANSYS, FEA, REFPROP) to support sizing, load cases, and design validation. You'll support configuration management, BOM control, and change processes using Teamcenter or equivalent PLM systems, participate in design reviews and interface control working groups, and support root cause investigations.
Shield AI's products include Hivemind autonomy software, V-BAT and X-BAT aircraft, and Aechelon simulation and synthetic reality technologies. The company has offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific, with technology actively supporting operations worldwide.
REQUIREMENTS:
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or related engineering discipline
- 7+ years of experience in mechanical design for aerospace, with direct propulsion hardware experience preferred
- Expert-level proficiency in CAD modeling and drawing creation (NX preferred) and application of GD&T
- Proven ability to work cross-functionally with production, machine shop personnel, and technicians to solve real-time hardware issues
- Familiarity with design for manufacturing, including machining processes, surface modeling, stack-up analysis, and fabrication limitations
- Hands-on experience developing assembly work instructions, troubleshooting build issues, and implementing hardware-driven design changes
- Experience with configuration management, PLM systems (Teamcenter), and BOM structure
- U.S. Citizenship or ability to comply with ITAR requirements; ability to obtain Secret clearance
PREFERRED QUALIFICATIONS:
- Experience with GFSSP, REFPROP, ANSYS, FEA, or other mechanical and thermal analysis tools
- Ability to write Python scripts for design automation, data analysis, or simulation support
- Proficient in interface control and tolerance stack-up analysis for complex assemblies
- Knowledge of fastening methods and joint design for high-vibration, aerospace environments
- Familiarity with high-temperature materials and design practices for thermally stressed components
- Prior experience designing hardware for internal combustion, turbine, or rocket propulsion systems, particularly in development or test environments
- M.S. or Ph.D. in Mechanical Engineering, Aerospace Engineering, or related engineering discipline
