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Shield AI is seeking a Senior Propulsion Design Engineer to support the development and delivery of propulsion hardware for the X-BAT platform, a next-generation UAV powered by a low-bypass turbofan engine. This role spans the full lifecycle of propulsion system components—from early layout and design through production release, test support, and flight operations.
You will be a key contributor to turning propulsion architecture into manufacturable, testable, and flight-ready hardware across the engine, fuel, oil, and bleed air systems. This is a hands-on, detail-oriented role requiring close collaboration with propulsion requirements engineers, technicians, machinists, production teams, airframe engineers, and flight test teams.
Key responsibilities include:
- Own the design and release of propulsion hardware supporting engine, fuel, oil, and bleed air systems
- Develop and maintain CAD models, drawings, and assemblies using Siemens NX with proper GD&T
- Translate propulsion architecture and requirements into hardware that is manufacturable, testable, and robust in flight
- Work directly with the machine shop, production, and technicians to support builds, resolve non-conformances, and drive iterative improvements
- Support test campaigns by providing hardware design support, instrumentation accommodation, and rapid iteration based on test findings
- Apply engineering judgment and analysis (hand calculations, ANSYS, FEA, GFSSP, REFPROP) to support sizing, load cases, and design validation
- Support configuration management, BOM control, and change processes using Teamcenter or equivalent PLM systems
- Participate in design reviews, interface control efforts, and root cause investigations related to propulsion hardware
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. The company has offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific.
REQUIREMENTS:
- Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or a related engineering discipline
- 5+ years of experience in aerospace hardware design, preferably supporting propulsion systems
- Proficiency in CAD modeling and drawing creation (NX preferred) with sound application of GD&T
- Experience working directly with production, technicians, and machine shops to resolve real-world build issues
- Understanding of design for manufacturing, including machining limitations, tolerance stack-ups, and assembly workflows
- Some hands-on experience developing assembly guidance and supporting hardware builds and test integration
- U.S. Citizenship or ability to comply with ITAR requirements
- Ability to obtain a S//SAR level security clearance desired
PREFERRED QUALIFICATIONS:
- Experience with jet propulsion systems on UAVs or tactical aircraft
- Familiarity with GFSSP, REFPROP, ANSYS, or FEA to support design trade studies and validation
- Ability to write Python scripts for design automation, analysis, or data processing
- Experience with interface control, fastener selection for high-vibration environments, and high-temperature materials
- Experience designing hardware in test-driven development environments with rapid iteration cycles
- M.S. in Aerospace Engineering or a related discipline
