Shield AI

Builds autonomous aircraft for defense

Staff Engineer - Tool Design

Design EngineeringConfirmed live in the last 24 hours

Full-timeDallas, TX, USA

About the Job

Requirements

Requires 7 or more years of experience in tooling design, mechanical design, or manufacturing engineering.
Requires a bachelor's degree in Mechanical, Aerospace, Industrial, Mechatronics, or a related engineering field.
Requires experience in prototype manufacturing in a startup or rapid-growth environment.
Requires a strong understanding of manufacturing processes, including machining, composites, avionics, or assembly.
Requires the ability to work in a fast-paced, high-pressure environment and adapt to changing priorities.

Responsibilities

Translate geometric dimensioning and tolerancing, key characteristics, and critical-to-quality requirements into tooling requirements, including datums, locators, clamps, tolerances, ergonomics, and electrostatic discharge and foreign object debris controls.
Design assembly jigs, drill and bond fixtures, composite molds and trim fixtures, go/no-go gauges, lifting and handling carts, and protective tooling using CATIA, NX, or SolidWorks.
Conduct finite element analysis and hand calculations to confirm stiffness, clamp loads, safety factors, and ergonomics.
Generate complete tool design packages, including 3D models, 2D drawings with geometric dimensioning and tolerancing, bills of materials, torque and fastener specifications, materials and finishes, lifting points, and safety labeling.
Lead design reviews with Manufacturing Engineering, Quality, Safety, and Launch teams, and perform human-factors evaluations.
Manage tool fabrication, oversee nonconformance report and engineering change request resolution, and support shop-floor prove-out.
Develop tool setup and care instructions, preventive maintenance plans, and inspection checklists.
Support first article activities, including coordinate measuring machine and laser-tracker alignment, gauge strategy, and dimensional validation.

Desired Qualifications

Knowledge of quality standards such as AS9100 or ISO 9001.
Familiarity with advanced manufacturing technologies such as additive manufacturing or automation systems.
Project management skills, including experience managing multiple priorities and deadlines.

Salary Range: 120000 to 190000 (Currency: USD) (Pay period: per-year-salary)

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.

Job Description:

The Senior Tool Design Engineer brings 7+ years of experience developing production tooling for complex aerospace systems. This role owns tooling throughout its lifecycle (concept, design, analysis, release, fabrication, and prove-out) ensuring safe, repeatable, first-time-right assembly. You will work cross-functionally with Manufacturing, Quality, and Safety to deliver robust tooling that supports pilot builds through rate production.

What you'll do:

Translate GD&T, key characteristics, and CTQs into tooling requirements (datums, locators, clamps, tolerances, ergonomics, ESD/FOD controls).
Design assembly jigs, drill/bond fixtures, composites molds & trim fixtures, go/no-go gauges, lifting/handling carts, and protective tooling using CATIA/NX/SolidWorks.
Conduct FEA and hand calculations to confirm stiffness, clamp loads, safety factors, and ergonomics.
Generate complete Tool Design Packages including 3D models, 2D drawings with GD&T, BOM, torque/fastener specs, materials/finishes, lifting points, and safety labeling.
Lead design reviews with ME, Quality, Safety, and Launch teams; perform human-factors evaluations.
Manage tool fabrication , oversee NCR/ECR resolution, and support shop-floor prove-out.
Develop Tool Setup & Care Instructions, PM plans, and inspection checklists.
Support First Article activities including CMM/laser-tracker alignment, gage strategy, and dimensional validation.

Tools & Skills

CATIA / NX / SolidWorks, 3DEXPERIENCE / Teamcenter, FEA tools, GD&T, metrology fundamentals, supplier manufacturing processes.

Required qualifications:

7+ years of experience in tooling design, mechanical design, or manufacturing engineering.
Bachelor’s degree in Mechanical, Aerospace, Industrial, Mechatronics, or related engineering field.
Experience in prototype manufacturing in a startup or rapid-growth environment.
Strong understanding of manufacturing processes, including machining, composites, avionics and/or assembly.
Demonstrated ability to work in a fast-paced, high-pressure environment and adapt to changing priorities

Preferred qualifications:

Knowledge of quality standards, such as AS9100 or ISO 9001.
Familiarity with advanced manufacturing technologies, such as additive manufacturing or automation systems.
Strong project management skills, including experience managing multiple priorities and deadlines.

Full-time regular employee offer package:

Pay within range listed + Bonus + Benefits + Equity

Temporary employee offer package:

Pay within range listed above + temporary benefits package (applicable after 60 days of employment)

Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location. All offers are contingent on a cleared background and possible reference check. Military fellows and part-time employees are not eligible for benefits. Please speak to your talent acquisition representative for more information.

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Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.

About the Company

Shield AI

Builds autonomous aircraft for defense

Shield AI builds autonomous aircraft and flight software for military and allied defense customers, with a focus on operations where conventional remote control breaks down. Its Hivemind AI pilot handles decisions during a mission, while the V-BAT aircraft gathers intelligence and locates targets. Aircraft makers use its software tools to develop and test their own autonomy, and its Aechelon business supplies visual and sensor simulation for pilot training. The company earns money from aircraft sales, autonomy software and contracted engineering and operational services. Shield AI was founded in 2015 and is headquartered in San Diego, California.

Company size: 1,001-5,000
Company stage: Series G
Total funding: $3.3B
Headquarters: San Diego, CA
Founded: 2015

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