Sr. Staff Mechanical Engineer - BlueSky (R5825)

Shield AI is a venture-backed defense-tech company developing intelligent systems for aerospace and defense applications. The Sr. Staff Mechanical Engineer will lead mechanical hardware development for advanced aerospace platforms across the product lifecycle, including design, analysis, integration, testing, production, and field support. The role involves hands-on technical work and collaboration with Engineering, Manufacturing, Supply Chain, and Quality teams to deliver reliable, high-performance systems.

Responsibilities:

• 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

Requirements:

• 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
• 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