# Staff Engineer, Mechanical Design - Launch and Recovery Systems (R4572)

**Company:** [Shield AI](https://hotfix.jobs/companies/shield-ai)
**Location:** Dallas, TX
**Role:** Hardware Engineering
**Salary:** $137k – $205k/yr
**Experience:** 7+ years
**Skills:** mechanical design, CAD, Solidworks, CATIA, Nx, structural analysis, FEA, thermal analysis, fatigue analysis, mil-std, aerospace gse, launch and recovery systems
**Posted:** 2026-03-27

> Lead the mechanical design, analysis, and testing of Ground Support Equipment including launch & recovery systems for Shield AI's next-gen autonomous UAS. Requires 7+ years aerospace mechanical design experience, CAD expertise, and structural/FEA analysis skills for rugged military systems.

## Job Description

## What you'll do
- Design and develop mechanical systems for Ground Support Equipment (GSE), including power units, transport structures, launch & recovery systems, and maintenance tools.
- Create detailed CAD models, drawings, and specifications for manufacturing and assembly.
- Conduct structural, thermal, and fatigue analysis to ensure durability and reliability of GSE in field environments.
- Collaborate with cross-functional teams to integrate GSE with aircraft systems and mission operations.
- Perform trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems.
- Oversee prototyping, testing, and validation of GSE designs to meet military and aviation standards.
- Develop technical documentation, test procedures, and support manuals for field operations.
- Work with suppliers and manufacturing partners to ensure cost-effective production and sustainment of GSE.
- Support flight test campaigns by providing engineering support for ground systems and test operations.

## Required qualifications
- 7+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
- Expertise in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout.
- Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
- Experience designing deployable, transportable, and field-ready aerospace support equipment.
- Knowledge of MIL-STD design requirements for aerospace ground support systems.
- Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
- Ability to work in a fast-paced, agile development environment with evolving priorities.
- Ability to obtain a S//SAR level security clearance desired.

## Preferred qualifications
- Experience designing UAS or military aircraft ground support equipment.
- Knowledge of power distribution, hydraulics, and environmental control systems for aerospace applications.
- Experience with DoD acquisition, sustainment, and field deployment strategies.
- Prior experience supporting military aircraft maintenance and sustainment operations.
- Active Secret or Top Secret clearance (or ability to obtain one).

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