Senior Propulsion Design Engineer (R4642)

f7d8749a-72d6-407c-bf98-292ea630c73a•Seattle, WA

About The Position

Shield AI is seeking a Senior Propulsion Design Engineer to support development and delivery of propulsion hardware for the X-BAT platform, a next-generation UAV powered by a low-bypass turbofan engine. The role spans the full lifecycle of propulsion system components, from early layout and design through production release, test support, and flight operations. The engineer will help turn propulsion architecture into manufacturable, testable, and flight-ready hardware across engine, fuel, oil, and bleed air systems. This is a hands-on, detail-oriented, cross-functional role involving close collaboration with propulsion responsible engineers, technicians, machinists, production, controls, airframe, and flight test teams. The position supports hardware design and release, build and test activities, design validation, configuration management, and improvement of propulsion hardware.

Requirements

Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, or a related engineering discipline.
At least 5 years of experience in aerospace hardware design, preferably supporting propulsion systems.
Proficiency in CAD modeling and drawing creation, with NX preferred, and 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.

Nice To Haves

Ability to obtain a S//SAR level security clearance.
Experience with jet propulsion systems on UAVs or tactical aircraft.
Familiarity with GFSSP, REFPROP, ANSYS, or FEA for 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.

Responsibilities

Own the design and release of propulsion hardware supporting engine, fuel, oil, and bleed air systems.
Develop and maintain CAD models, drawings, and assemblies using Siemens NX, applying appropriate GD&T.
Translate propulsion architecture and requirements into hardware that is manufacturable, testable, and robust in flight.
Work with the machine shop, production, and technicians to support builds, resolve non-conformances, and drive iterative improvements.
Support test campaigns with hardware design support, instrumentation accommodation, and rapid iteration based on test findings.
Apply engineering judgment and analysis, including hand calculations and tools such as ANSYS, FEA, GFSSP, and 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.