Design and manage production tooling for complex aerospace systems from concept through fabrication and prove-out. Responsibilities include designing fixtures, molds, gauges, carts, and protective tooling; conducting FEA and calculations; creating detailed tool packages; leading cross-functional reviews; managing fabrication and issue resolution; developing setup, maintenance, and inspection documentation; and supporting first article dimensional validation.
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.
- CATIA / NX / SolidWorks, 3DEXPERIENCE / Teamcenter, FEA tools, GD&T, metrology fundamentals, supplier manufacturing processes.
Tools & Skills
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.
Similar Jobs at Shield AI
Aerospace • Artificial Intelligence • Machine Learning • Robotics • Software
Lead Shield AI’s digital factory and AI-enabled manufacturing roadmap. Deploy and improve MES, integrate ERP, PLM, QMS, automation, equipment, and connected factory infrastructure, and establish the digital thread across engineering, production, quality, maintenance, and supply chain. Identify and implement AI, predictive maintenance, machine vision, digital twin, analytics, and automation solutions while leading complex cross-functional factory transformation initiatives.
Top Skills:
Advanced AnalyticsArtificial IntelligenceDigital TwinsEnterprise Resource Planning (Erp)Factory AutomationIndustrial ControlsMachine LearningMachine VisionManufacturing Execution Systems (Mes)Product Lifecycle Management (Plm)Programmable Logic Controllers (Plcs)Quality Management Systems (Qms)
Aerospace • Artificial Intelligence • Machine Learning • Robotics • Software
Leads manufacturing integration and production readiness for aerospace and defense platforms. Develops final assembly processes, coordinates system-level builds, drives DFM/DFA reviews, resolves integration issues through root cause analysis, defines work instructions and quality standards, supports product transitions into manufacturing, and collaborates across design, production, quality, supply chain, and test engineering. Mentors junior engineers and improves reliability, producibility, and production scalability.
Top Skills:
3Dexperience5SAs9100CadDfaDfmErpIso 9001MesPlmQmsTeamcenter
Aerospace • Artificial Intelligence • Machine Learning • Robotics • Software
Leads manufacturing engineering for aerospace propulsion and fluid-system hardware from development through production. Responsibilities include process and tooling development, engine and fuel/oil system integration, DFM/DFA reviews, root-cause investigations, corrective actions, work instructions, inspection methods, supplier qualification, process validation, production readiness, system troubleshooting, and reliability improvements. Collaborates across design, production, quality, supply chain, and test teams while mentoring junior engineers.
Top Skills:
3DexperienceAs9100CadErpIso 9001MesPlmQmsTeamcenter
What you need to know about the Seattle Tech Scene
Home to tech titans like Microsoft and Amazon, Seattle punches far above its weight in innovation. But its surrounding mountains, sprinkled with world-famous hiking trails and climbing routes, make the city a destination for outdoorsy types as well. Established as a logging town before shifting to shipbuilding and logistics, the Emerald City is now known for its contributions to aerospace, software, biotech and cloud computing. And its status as a thriving tech ecosystem is attracting out-of-town companies looking to establish new tech and engineering hubs.
Key Facts About Seattle Tech
- Number of Tech Workers: 287,000; 13% of overall workforce (2024 CompTIA survey)
- Major Tech Employers: Amazon, Microsoft, Meta, Google
- Key Industries: Artificial intelligence, cloud computing, software, biotechnology, game development
- Funding Landscape: $3.1 billion in venture capital funding in 2024 (Pitchbook)
- Notable Investors: Madrona, Fuse, Tola, Maveron
- Research Centers and Universities: University of Washington, Seattle University, Seattle Pacific University, Allen Institute for Brain Science, Bill & Melinda Gates Foundation, Seattle Children’s Research Institute
