Senior Propulsion Design Engineer

Join to apply for the Senior Propulsion Design Engineer role at Shield AI3 days ago Be among the first 25 applicantsJoin to apply for the Senior Propulsion Design Engineer role at Shield AIGet AI-powered advice on this job and more exclusive features.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 Follow Shield AI on LinkedIn, X and Instagram.Job Description:Shield AI is building intelligent aircraft powered by AI pilots, capable of operating autonomously in the world’s most complex environments. As a Senior Propulsion Design Engineer on our next-gen UAV program, you’ll lead the detailed mechanical design of propulsion-related hardware from mounts and inlets to structural interfaces, fuel manifolds, and ducting.You’ll join at the earliest stages of platform development and will be directly responsible for translating propulsion architecture into manufacturable, testable hardware. This is a highly collaborative role that sits at the intersection of mechanical design, propulsion integration, and flight hardware validation.We’re looking for a senior engineer with excellent CAD and design-for-manufacture skills, deep mechanical intuition, and a passion for building hardware that performs in extreme, real-world conditions.What you will do in this role:Own the end-to-end mechanical design of propulsion components, including engine mounts, ducts, valves, fuel manifolds, and structural interfacesCreate detailed 3D models and 2D drawings in Creo or NX with full GD&T and tolerancing for flight hardwareWork closely with propulsion architects and fluids/fuel engineers to convert system requirements into hardware interfaces and assembliesOptimize for packaging, weight, performance, and manufacturability within tight space constraintsDrive design reviews, interface control documents (ICDs), and configuration management across propulsion subsystemsSupport the development of test fixtures and tooling for ground and flight validationCollaborate with thermal and structural analysts to ensure your designs meet performance and durability requirementsLead prototype fabrication efforts, including coordination with machine shops and vendorsDocument all design work, including material selection, justification of features, design rationale, and interface managementInterface regularly with hardware test engineers to close the loop between design and real-world performanceRequired qualifications:Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or related discipline8+ years of experience designing mechanical hardware for aerospace, UAV, or defense systemsExpert proficiency with Creo or NX, including parametric modeling, assemblies, and 2D drawing creationStrong understanding of GD&T, tolerances, material selection, and aerospace manufacturing methodsHands-on experience with flight or propulsion-related hardware design, particularly mounts, ducts, and engine integrationKnowledge of design for manufacturability (DFM) and design for assembly (DFA) principlesFamiliarity with mechanical stress, vibration, and thermal effects on propulsion componentsComfortable working in a fast-paced R&D environment with limited initial requirementsExcellent communication and documentation skillsPreferred qualifications:Master’s degree in Mechanical Engineering or Aerospace EngineeringExperience designing for jet propulsion or hybrid-electric aircraftExposure to MIL-STD environments, DO-160 testing, or aerospace hardware qualification processesFamiliarity with Thermal Desktop, ANSYS, or structural FEA toolsPrior experience with in-house and outsourced prototyping and production workflowsActive or prior DoD clearance (not required)$114,989 - $172,483 a year#LCFull-time regular employee offer package:Pay within range listed + Bonus + Benefits + EquityTemporary 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.Seniority levelSeniority levelAssociateEmployment typeEmployment typeFull-timeJob functionJob functionEngineering and Information TechnologyIndustriesSoftware DevelopmentReferrals increase your chances of interviewing at Shield AI by 2xGet notified about new Senior Design Engineer jobs in Dallas, TX.Mid-Level HVAC Mechanical Design Engineer – Multiple SectorsGarland, TX $94,393.00-$100,994.00 1 week agoSr Manager - Plan Design and DevelopmentDallas, TX $91,225.00-$172,200.00 6 days agoGarland, TX $103,146.00-$123,529.00 10 months agoSenior Mechanical Engineer - Kiewit Power EngineeringArchitecture Sr. Design Manager- Food & Beverage MarketDesign & Construction Manager, EV ChargingDallas, TX $95,000.00-$140,000.00 3 days agoArchitecture and Design Firm | Senior Project Architect & Project ManagerDallas-Fort Worth Metroplex $120,000.00-$150,000.00 1 month agoSr. Manager Development & Design Engineering (Interconnect)Sr. Construction Manager, GES NACF Design and ConstructionDallas, TX $81,200.00-$181,600.00 2 weeks agoSenior Mechanical Engineer : Energy & Power (Fort Worth) 23362Dallas, TX $116,400.00-$170,000.00 2 weeks agoConstruction Manager II, NACF Design and Construction, NACF Design and ConstructionSenior Mechanical Engineer- Mission Critical, Traveler (AFG)Senior Architectural Design and Project Manager (Senior Airport Planner)Architecture Sr. Design Manager- Japanese SpeakingVisual Design Manager (Graphic Design Focused)Senior Mechanical Engineer - Mission CriticalSenior Manager, Hardware Design EngineeringWe’re unlocking community knowledge in a new way. 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Created: 2025-09-17