Staff Engineer, Mechanical Design

About the role

The Staff Mechanical Design Engineer, Ground Support Equipment at Shield AI is responsible for the conception, detailed design, and delivery of critical ground support hardware that directly enables mission readiness. You will own the development of field-deployable support structures, handling devices, and maintenance interfaces that ensure aircraft readiness in demanding military environments and austere conditions. This position requires you to translate complex, high-stakes defense requirements into robust, manufacturable hardware solutions while coordinating seamlessly across mechanical design, manufacturing, and operational teams. You will guide the full lifecycle of Ground Support Equipment (GSE), from initial concept and requirements capture through detailed design, structural validation, testing, and final documentation. The role demands a high level of ownership, ensuring that every bracket, fixture, and interface is designed to meet strict safety, reliability, and operational standards. You will act as a key mechanical authority, resolving design conflicts and making critical trade-offs to keep programs on schedule. Collaboration with flight operations and test teams is essential to ensure that support workflows align with real-world mission profiles, maintenance procedures, and constraints. Ultimately, you will define the mechanical and electrical interfaces between aircraft and support gear, establishing the secure and repeatable connection sequences that field crews rely on.

Key facts

What you'll do

• Design structural frames, handling fixtures, and interface adapters for next-generation UAS, adhering to demanding tolerance and durability targets that ensure long-term operational reliability.
• Create detailed 3D models and 2D technical drawings of GSE components, serving as the authoritative definition for fabrication, assembly, and inspection activities.
• Perform structural analysis and physical testing to validate performance of support equipment under operational conditions, including load, vibration, and environmental extremes.
• Develop, execute, and document test procedures that confirm support equipment functions safely and correctly during aircraft maintenance, handling, and rapid turnaround scenarios.
• Work closely with manufacturing specialists to refine designs for reliable production, ensuring processes are optimized for shop floor assembly, quality, and cost-effectiveness.
• Collaborate with flight operations teams to ensure that support workflows, handling sequences, and interface procedures align with real-world mission profiles and constraints.
• Specify mechanical and electrical interfaces between aircraft and support gear, defining secure and repeatable connection sequences that prevent misapplication and enhance safety.
• Create comprehensive configuration records, procedures, and technical documentation that allow field crews to service, maintain, and repair equipment under varied deployment and storage conditions.
• Perform material and component selection based on environmental extremes, vibration profiles, shock loads, and rigorous logistics requirements such as packaging and transportability.
• Drive design for manufacturability and logistics, ensuring that GSE can be produced consistently, maintained in the field, and supported over the full lifecycle of the program.
• Partner with suppliers and vendors to validate component availability, manage design changes, and ensure compliance with defense-specific supply chain and traceability requirements.
• Implement and maintain engineering best practices, standards, and lessons learned across GSE projects to improve quality, reduce risk, and accelerate delivery.
• Support the development of synthetic reality and simulation tools, such as Aechelon, to validate GSE fit, access, and function in virtual environments before physical build.
• Act as the mechanical domain expert during design reviews, safety assessments, and customer interactions, clearly articulating design decisions and verification results.

Requirements

• Hold a degree in mechanical engineering or a closely related technical discipline; a bachelor's degree is mandatory, and a master's degree is strongly preferred.
• Possess hands-on experience performing structural analysis of metal and composite assemblies, including failure mode identification and mitigation.
• Demonstrated skill in using CAD software to produce intricate parts, assemblies, and detailed technical drawings that meet defense industry standards.
• Understand how ground support systems integrate with unmanned aircraft during maintenance, turnaround cycles, and storage operations.
• Familiarity with relevant test methods, documentation standards, and defense-related compliance topics such as ITAR and export control is required.
• Ability to interpret technical requirements and convert them into hardware specifications, acceptance criteria, verification test methods, and detailed engineering drawings.
• Experience applying engineering judgment to solve complex mechanical problems in dynamic, deadline-driven project environments.
• Strong written and verbal communication skills to coordinate with cross-functional teams, prepare technical reports, and interface with government customers.

Nice to have

• Experience with simulation tools that predict structural behavior under varied loading scenarios, such as finite element analysis and multi-body dynamics.
• Background in aerospace ground systems, defense programs, and military platform integration providing direct familiarity with GSE workflows and constraints.

Practical notes

This description outlines the essential functions and requirements; it does not exclude other appropriate duties. Shield AI reserves the right to modify roles, responsibilities, and requirements as operational needs evolve. The position is based in Dallas, Texas, and requires full-time onsite engagement. No specific visa sponsorship details or travel requirements are outlined in this posting.