At Shield AI, Prototype Manufacturing is where engineering becomes reality. Our team builds the first aircraft, develops the manufacturing processes, solves complex technical challenges, and establishes the manufacturing foundation that enables scalable production. Every prototype directly influences the future of our products and the capabilities delivered to our customers.
We are seeking an experienced Lead Prototype Technician (Level 5) to join our Prototype & New Product Launch team. This is not a traditional aerospace technician role. You will build first-of-kind autonomous aircraft, develop manufacturing processes, solve challenging technical problems, influence product design through Design for Manufacturability (DFM), and help define how our products transition from prototype to production.
As a Lead Prototype Technician, you will serve as the technical cornerstone of Prototype Manufacturing by transforming engineering intent into flight-ready hardware while driving continuous improvement across manufacturing processes. You will partner closely with Engineering, Manufacturing Engineering, Quality, and Production to ensure our prototype builds are successful today and scalable for tomorrow.
What you'll do:
- Build prototype, developmental, and first article aircraft from engineering concept through flight-ready hardware.
- Perform precision drilling, reaming, countersinking, riveting, fastening, torqueing, safety wiring, structural assembly, and mechanical integration.
- Execute advanced composite manufacturing including wet layup, bonding, trimming, machining, vacuum bagging, structural repairs, finishing, and final assembly.
- Perform complex aircraft modifications and structural repairs.
- Interpret engineering drawings, CAD models, GD&T, specifications, and manufacturing documentation.
- Partner with Design Engineering to provide Design for Manufacturability (DFM) feedback.
- Develop and improve manufacturing work instructions, build sequences, tooling concepts, fixtures, and standardized assembly methods.
- Support engineering validation, qualification builds, and flight test campaigns.
- Fabricate custom brackets, tooling, fixtures, and prototype hardware.
- Mentor Prototype Technicians while establishing best practices and craftsmanship standards.
Key responsibilities:
- Prototype Manufacturing Excellence
- Design for Manufacturability (DFM)
- Manufacturing Process Development
- Cross Functional Leadership
- Technical Leadership
What success looks like:
- Deliver complex prototype hardware with exceptional quality.
- Solve manufacturing challenges before they become production issues.
- Influence engineering through practical manufacturing expertise.
- Develop repeatable manufacturing processes.
- Mentor technicians and elevate team capability.
Required qualifications:
- 10+ years of aerospace manufacturing or prototype experience.
- Extensive aircraft structural assembly experience.
- Advanced composites experience including wet layup and structural repair.
- Experience with engineering development builds.
- Ability to interpret complex engineering drawings and GD&T.
- Strong troubleshooting and problem-solving skills.
- Ability to obtain and maintain a U.S. Security Clearance.
Preferred qualifications:
- Military aircraft, UAV, eVTOL, or rotorcraft experience.
- Prototype-to-production transition experience.
- AS9100 experience.
- A&P License or equivalent.
- Military aviation maintenance experience.
- Leadership or mentoring experience.
Why join Shield AI:
Unlike traditional aerospace manufacturing, our Prototype Manufacturing team works directly alongside Engineering to create the next generation of autonomous aircraft. You'll influence design decisions, define manufacturing processes, mentor other technicians, and build technology that protects those who serve.
Shield AI offers competitive compensation, equity participation, comprehensive medical, dental, and vision benefits, 401(k), generous paid time off, professional development opportunities, and the chance to work on some of the world's most advanced autonomous aircraft systems.
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