Staff Engineer, Tool Design (R4967)

Shield AI is hiring a Staff Engineer, Tool Design (R4967) in Dallas, United States. It pays $120k-$190k a year and Level rates it ; you can apply on Shield AI.

Level's read on this job

On Level's scale, this role is Little AI ●○○○: aI is not part of the work.
Level classifies it as a lead role.
Level lists 664 other open roles at Shield AI.

AI in this role

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. 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.

What 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.

Required 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

Preferred 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. ### 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.

How we rate this

Staff Engineer, Tool Design (R4967) at Shield AI rates 33 out of 100 for how much of the daily work is AI. That makes it Little AI (AI Level 1 of 4). The level is about AI in the job, not seniority.

Classification

Little AI. AI is not part of the work.

●●●● Builds AI80 to 100
●●●○ Works on AI60 to 79
●●○○ Uses AI40 to 59
●○○○ Little AI0 to 39

Levels come from how often the tools, models and workflows of the role are named in the posting itself. Read the description and count the AI tools, models and workflows it names.