Senior Propulsion Design Engineer (R4642)

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.