Staff Engineer, Mechanical - Harness Design

Shield AI, Inc.

Job Overview

Location

Dallas, Texas

Job Type

Full-time

Full Job Description

📋 Description

• As a Staff Engineer, Mechanical - Harness Design at Shield AI, you will play a critical role in advancing the company’s mission to protect service members and civilians through intelligent autonomous systems by leading the design and integration of complex electrical harnesses for next-generation aircraft like the V-BAT and X-BAT, ensuring reliability, performance, and safety in GPS/RF-denied environments.
• You will own the end-to-end mechanical design of wire harnesses, including routing, clamping, strain relief, and protection systems, working closely with electrical, avionics, and systems engineers to ensure seamless integration within airframe structures while meeting stringent aerospace standards for vibration, thermal, and EMI/EMC performance.
• Day-to-day responsibilities include creating detailed 3D harness models and 2D manufacturing drawings using CAD tools (primarily Siemens NX or CATIA), conducting harness layout reviews, generating bills of materials (BOMs), and collaborating with manufacturing and test teams to validate designs for producibility, serviceability, and compliance with AS9100 and IPC/WHMA-A-620 standards.
• You will perform mechanical analysis to assess harness durability under flight loads, including vibration, shock, and thermal cycling, using simulation tools or hand calculations to validate designs against environmental requirements and support qualification testing.
• You will interface with suppliers and internal fabrication teams to review prototype builds, identify design-for-manufacturing (DFM) opportunities, and drive continuous improvement in harness assembly processes, including labeling, shielding, and grounding practices.
• You will participate in design reviews, failure investigations, and cross-functional technical meetings, providing mechanical expertise to resolve integration challenges and support airworthiness documentation for certification efforts.
• You will mentor junior engineers and contribute to the development of harness design standards, best practices, and knowledge-sharing initiatives within the avionics hardware team, fostering a culture of technical excellence and innovation.
• Shield AI’s avionics hardware team is a multidisciplinary group of engineers dedicated to pushing the boundaries of autonomous aviation, combining deep expertise in aerospace systems, electronics, and mechanical design to deliver rugged, intelligent aircraft that operate where others cannot.
• The company fosters a mission-driven, fast-paced culture rooted in innovation, accountability, and technical rigor, where engineers are empowered to take ownership, solve hard problems, and see their work directly impact real-world defense and security operations across global theaters.
• In this role, you will develop deep expertise in aerospace harness design, gain exposure to cutting-edge autonomous systems, and grow as a technical leader by influencing design decisions that shape the future of unmanned aviation—positioning you for advancement into senior technical or architectural roles within Shield AI’s expanding engineering organization.

🎯 Requirements

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related technical field; advanced degree preferred.
• 5+ years of experience in mechanical design of electrical harnesses, cable assemblies, or interconnect systems for aerospace, defense, or high-reliability electronic applications.
• Proficiency in 3D CAD software (Siemens NX, CATIA, or SolidWorks) for harness routing, modeling, and detailed drafting, with experience in creating manufacturing-ready drawings and BOMs.
• Strong understanding of harness design principles, including strain relief, bending radius, shielding, grounding, and protection methods (e.g., conduit, sleeving, lacing) per IPC/WHMA-A-620 and AS9100 standards.
• Experience with mechanical analysis for vibration, shock, and thermal environments, preferably using simulation tools or validated hand calculations.
• Familiarity with aerospace manufacturing processes, assembly techniques, and quality systems (AS9100 preferred); ability to collaborate effectively with production and test teams.

🏖️ Benefits

• Competitive salary and performance-based bonuses aligned with individual and company impact.
• Comprehensive health, dental, and vision insurance plans for employees and dependents.
• Generous paid time off, including vacation, sick leave, and company-observed holidays.
• 401(k) retirement plan with company matching to support long-term financial security.
• Ongoing professional development opportunities, including technical training, conference attendance, and tuition reimbursement for relevant education.
• Access to cutting-edge projects in autonomous aviation, with the chance to work on systems deployed in real-world operational environments.

Skills & Technologies

Senior

Onsite

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Shield AI, Inc.

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About Shield AI, Inc.

Shield AI develops autonomous systems and artificial intelligence for defense and commercial aviation. Its Hivemind AI pilot enables unmanned aircraft and drones to operate without GPS, communications, or remote pilots. The company’s products include the V-BAT vertical takeoff and landing drone and software for fighter aircraft autonomy. Founded in 2015, Shield AI serves U.S. and allied military forces, focusing on contested environments and battlefield applications. The company integrates machine learning, sensor fusion, and edge computing to provide resilient, intelligent platforms for intelligence, surveillance, reconnaissance, and strike missions.

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