Staff Engineer, Tool Design (R4967)

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.

• 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.

Job Description 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.