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Shield AI

Posted 5 months ago

Open

Senior Propulsion Design Engineer (R4642)

DallasOn-siteFull-time

AI Summary

Designs and releases propulsion hardware for the X-BAT UAV platform, spanning engine, fuel, oil, and bleed air systems from layout through production and flight test.

About this role

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 and X-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With 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:

We are 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 role is hands-on, detail-oriented, and highly cross-functional - requiring close collaboration with propulsion REs, technicians, machinists, production, controls, airframe, and flight test teams.

What you will do in this role:

  • Own the design and release of propulsion hardware supporting the 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 (e.g., hand calcs, 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.
  • Participate in design reviews, interface control efforts, and root cause investigations related to propulsion hardware.

    • Required qualifications:

  • 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.

    • 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.

    • Skills

    AnsysBOM ControlConfiguration ManagementFastener SelectionFEAGD&TGFSSPHigh-temperature MaterialsInstrumentationITARMachiningPLMPythonRefPropSiemens NXTeamcenterTest-driven DevelopmentTolerance Stack-ups

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