Staff Engineer, Mechanical Test (R5475)

Do you enjoy working in a dynamic lab environment and being part of a design team that will impact the safety of service members and civilians? If so, we want your help designing the next generation aircraft at Shield AI. The Mechanical Test team’s mission is to inform Shield AI hardware design by quantifying product performance and experience with custom measurement tools, and specialized analysis.

We are seeking a highly skilled and detail-oriented Structures/Mechanical Test Engineer to support the development, testing, and validation of advanced mechanical systems. The ideal candidate will have strong hands-on experience with hydraulic systems, various sensor technologies (e.g., force, pressure, strain, displacement), be proficient in python for test automation and data analysis, and demonstrate expert level proficiency in CAD tools such as NX.

Develop and execute test plans to validate mechanical performance, structural integrity, and environmental durability from start to finish.

Design, build, and operate test fixtures and systems involving hydraulic actuation, mechanical linkages, and sensor instrumentation.

Integrate and calibrate a range of sensors (e.g., load cells, pressure transducers, strain gauges, accelerometers) into test setups for accurate data collection.

Create and maintain python scripts to provide automation, signal processing, and result visualization.

Analyze test data, troubleshoot system behaviors, and generate detailed technical reports with design feedback.

Collaborate with cross-functional teams including mechanical design, systems, and electrical engineering to define test requirements, run test campaigns and deliver high quality results.

Lead CAD design of custom test equipment, prototypes, fixtures, and components, ensuring manufacturability and safety.

Perform Finite Element Analysis to simulate mechanical performance, validate design assumptions, and correlate analytical results with test data.

Work with metallic/composite materials in the design, fabrication, and testing of mechanical components, with consideration for their unique properties such as anisotropy, delamination risk, and layup configuration.

Support lab safety protocols, equipment maintenance, and continuous improvement of test capabilities.