Senior Propulsion Design Engineer

Job Description:

We are seeking a Senior Propulsion Design Engineer to support the mechanical design of propulsion system hardware for a low-bypass turbofan-powered UAV. This role covers the full lifecycle of components associated with the engine, oil, fuel, and bleed air systems—from concept and layout through production release and test iteration.

You will contribute to the design and delivery of flight-critical propulsion hardware, ensuring it is well-integrated, manufacturable, and reliable. You’ll collaborate closely with Responsible Engineers, technicians, and production teams to bring architecture to life and support test and flight programs with speed and rigor.

We’re looking for a hands-on engineer with strong CAD skills, solid understanding of manufacturing constraints, and the ability to move quickly without sacrificing quality or detail.

What you will do in this role:

• Support the design of propulsion components and subsystems from concept through production release.
• Create and maintain CAD models, detailed drawings, and assemblies using Siemens NX with applied GD&T.
• Contribute to the development and application of propulsion design standards and team best practices.
• Work closely with production, machine shop, and technician teams to support builds and resolve non-conformances.
• Assist in developing work instructions, assembly guidance, and documentation for repeatable hardware builds.
• Design with a strong awareness of manufacturability, machining limitations, and material and tolerance constraints.
• Apply basic engineering analysis and judgment (e.g., hand calcs, ANSYS, FEA, GFSSP, REFPROP) to support sizing and design validation.
• Support configuration control, BOM structure, and change processes within Teamcenter or an equivalent PLM.
• Participate in design reviews, interface discussions, and problem-solving efforts during hardware development.

Required qualifications:

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.
• 5+ years of experience in aerospace mechanical design, preferably with propulsion hardware.
• Proficiency in CAD modeling and drawing creation (NX preferred) and sound application of GD&T.
• Ability to work effectively with production, technicians, and machine shop teams to resolve design and build issues.
• Understanding of design for manufacturing, including stack-up analysis, surface modeling, and fabrication constraints.
• Some hands-on experience developing or supporting assembly instructions and resolving build issues.
• Familiarity with configuration management and PLM systems such as Teamcenter.
• U.S. Citizenship or ability to comply with ITAR requirements.

Preferred qualifications:

• Experience with GFSSP, REFPROP, ANSYS, FEA, or similar tools for analysis and validation.
• Ability to write Python scripts for design automation, simulation, or data processing.
• Proficiency in tolerance stack-up analysis and interface control for complex assemblies.
• Knowledge of fastening methods and design for vibration environments.
• Familiarity with high-temperature materials and thermally constrained mechanical systems.
• Experience designing for internal combustion, turbine, or rocket propulsion systems, particularly in development or test settings.
• M.S. in Mechanical Engineering, Aerospace Engineering, or a related discipline.

$114,989 - $172,483 a year

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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.