Staff Engineer, Tool Design (R4967)

Shield AI•Seattle, WA

About The Position

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. The Senior Tool Design Engineer brings 7+ years of experience developing production tooling for complex aerospace systems. This role owns tooling throughout its lifecycle (concept, design, analysis, release, fabrication, and prove-out) ensuring safe, repeatable, first-time-right assembly. You will work cross-functionally with Manufacturing, Quality, and Safety to deliver robust tooling that supports pilot builds through rate production.

Requirements

7+ years of experience in tooling design, mechanical design, or manufacturing engineering.
Bachelor’s degree in Mechanical, Aerospace, Industrial, Mechatronics, or related engineering field.
Experience in prototype manufacturing in a startup or rapid-growth environment.
Strong understanding of manufacturing processes, including machining, composites, avionics and/or assembly.
Demonstrated ability to work in a fast-paced, high-pressure environment and adapt to changing priorities.

Nice To Haves

Knowledge of quality standards, such as AS9100 or ISO 9001.
Familiarity with advanced manufacturing technologies, such as additive manufacturing or automation systems.
Strong project management skills, including experience managing multiple priorities and deadlines.

Responsibilities

Translate GD&T, key characteristics, and CTQs into tooling requirements (datums, locators, clamps, tolerances, ergonomics, ESD/FOD controls).
Design assembly jigs, drill/bond fixtures, composites molds & trim fixtures, go/no-go gauges, lifting/handling carts, and protective tooling using CATIA/NX/SolidWorks.
Conduct FEA and hand calculations to confirm stiffness, clamp loads, safety factors, and ergonomics.
Generate complete Tool Design Packages including 3D models, 2D drawings with GD&T, BOM, torque/fastener specs, materials/finishes, lifting points, and safety labeling.
Lead design reviews with ME, Quality, Safety, and Launch teams; perform human-factors evaluations.
Manage tool fabrication, oversee NCR/ECR resolution, and support shop-floor prove-out.
Develop Tool Setup & Care Instructions, PM plans, and inspection checklists.
Support First Article activities including CMM/laser-tracker alignment, gage strategy, and dimensional validation.