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[JOBS/SIMULATION/STAFF ENGINEER, TOOL DESIGN (R4299)]
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POSTING ACTIVE · REQ-ACC21 · FY25.Q4

Staff Engineer, Tool Design (R4299)

Shield AI
[ COMPANY ]
Shield AI
[ LOCATION ]
Dallas, Texas
[ POSTED ]
2025.12.15
[ REQ ID ]
REQ-ACC21
[ COMPENSATION RANGE · ANNUAL · BASE ]
$120,000 – $190,000USD
MIDPOINT
$155,000
SPREAD
$70,000
LEVEL
LEAD
§ 01OVERVIEW
Founded in 2015, 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 and V-BAT and X-BAT aircraft. With offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific, Shield AI’s technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.
Job Description:
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.
§ 02WHAT YOU'LL DO
  • 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.
    • Tools & Skills
  • CATIA / NX / SolidWorks, 3DEXPERIENCE / Teamcenter, FEA tools, GD&T, metrology fundamentals, supplier manufacturing processes.
§ 03REQUIRED QUALIFICATIONS
  • 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
§ 04PREFERRED QUALIFICATIONS
  • 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.
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.
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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.
QUESTIONS AND ANSWERS
How much does the Staff Engineer, Tool Design (R4299) at Shield AI pay?
The posting lists a range of $120K–$190K per year. Ranges reflect what Shield AI publicly declared on the source posting.
Where is this Staff Engineer, Tool Design (R4299) role based?
The role is based in Dallas, Texas.
What experience does Shield AI expect for this role?
The posting is tagged as a lead-level role, typically 7+ years of experience. Check the requirements section for specifics.
Where is Shield AI headquartered?
Shield AI is headquartered in San Diego, USA.
How was this posting sourced?
This role was pulled directly from Shield AI's Lever careers site. Apply links open in the employer's own ATS — no reposts or aggregator middleware.
[ APPLICATION ROUTE ]LEVER · External ATS
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