Senior Propulsion Design Engineer (R4641)

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:

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.

• 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.

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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.

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.