Principal Propulsion Design Engineer
Shield AI
Design
Dallas County, TX, USA
Posted on Jun 20, 2025
Founded in 2015, Shield AI is a venture-backed defense technology company with the mission of protecting service members and civilians with intelligent, autonomous systems. Its products include Hivemind Enterprise—EdgeOS, Pilot, Commander, and Forge—as well as V-BAT and Sentient Vision Systems (wide-area motion imaging software). With offices in San Diego, Dallas, Washington, D.C., Abu Dhabi (UAE), Kyiv (Ukraine), and Melbourne (Australia), Shield AI’s technology actively supports U.S. and allied operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X and Instagram.
Job Description:
Shield AI builds intelligent aircraft that fly autonomously in denied environments to protect service members and civilians. As a Principal Propulsion Design Engineer on our next-gen UAV program, you will own the mechanical design strategy for the platform’s propulsion hardware—from engine mounts and fuel manifolds to ducting, exhaust interfaces, and structural supports.
You’ll drive the detailed mechanical design of complex assemblies in a high-performance, thermally stressed environment. This role combines high-fidelity 3D modeling, deep understanding of flight hardware durability, and close collaboration with propulsion, thermal, and structural teams to deliver fully integrated, flight-ready systems.
This is a leadership role for a technical expert with 15+ years in aerospace mechanical design, ideally focused on propulsion subsystems or other flight-critical components.
What you will do in this role:
- Serve as mechanical design lead for all propulsion hardware and subsystem components on the next-gen platform
- Architect and deliver fully detailed 3D models, assemblies, and 2D manufacturing drawings using Creo or NX, applying GD&T to aerospace standards
- Lead design of engine mounts, ducts, inlets, exhausts, isolation brackets, fuel routing hardware, and propulsion housing structures
- Ensure mechanical compatibility across propulsion, thermal, and structural interfaces while optimizing for weight, manufacturability, and endurance
- Guide development of Interface Control Documents (ICDs), Bills of Materials (BOMs), and configuration control processes for propulsion hardware
- Collaborate with analysts to ensure hardware is robust to thermal, vibrational, and dynamic loads expected in flight
- Interface with manufacturing and supply chain teams to support prototyping, production-readiness, and vendor coordination
- Mentor a growing team of mechanical and propulsion-focused designers, setting standards for quality and reliability
- Present design decisions at formal and informal reviews, advocating for practical, mission-aligned solutions
- Lead root-cause investigations and iterative redesign efforts based on test and flight feedback
Required qualifications:
- Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related discipline
- 15+ years of mechanical design experience with aerospace hardware, ideally propulsion-related
- Expert-level proficiency with Creo or NX for complex, tolerance-critical design work
- Strong knowledge of GD&T, tolerance stack-up, lightweight structural design, and aerospace materials
- Proven experience designing and releasing flight-critical hardware, especially in propulsion environments (e.g., high-temp, high-vibration, confined volumes)
- Familiarity with thermal, vibrational, and shock environments typical of aircraft propulsion systems
- Demonstrated ability to collaborate across disciplines, lead design reviews, and influence system architecture
- Excellent documentation, presentation, and technical leadership skills
Preferred qualifications:
- MS in Mechanical Engineering or Aerospace Design
- Experience with jet engine integration, UAV propulsion systems, or missile/aero-vehicle hardware
- Familiarity with AS9100, MIL-STD, or DO-160 requirements for aerospace hardware
- Exposure to FEA workflows (thermal and structural), rapid prototyping, and test-validated hardware loops
- Experience leading supplier design engagements or managing design-to-manufacture transitions
- Active or previous DoD clearance (not required)
#LI-JW2
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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.
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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.