Prototype Lead
Location: Frisco, TX
Pay Range: $43.00–$64.00/hour
Direct position
Build the Future of Autonomous Aircraft
At Shield AI, Prototype Manufacturing is where engineering concepts become flight-ready reality. Our team builds the first aircraft, develops the manufacturing processes, solves complex technical challenges, and establishes the foundation for scalable production.
We are seeking an experienced Prototype Lead to join our Prototype & New Product Launch team. This is a hands-on technical leadership role for someone who thrives on building first-of-kind aerospace hardware, solving difficult manufacturing challenges, and turning engineering intent into high-quality, flight-ready aircraft.
As a Prototype Lead, you will be a technical cornerstone of Prototype Manufacturing. You’ll work directly with Engineering, Manufacturing Engineering, Quality, and Production to build developmental aircraft, influence product design through Design for Manufacturability (DFM), develop repeatable manufacturing processes, and help transition innovative designs from prototype to production.
What You'll Do
- Lead the hands-on build of 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, troubleshooting, and structural repairs.
- Interpret engineering drawings, CAD models, GD&T, specifications, and manufacturing documentation.
- Partner with Design Engineering to identify manufacturing challenges and provide actionable DFM feedback.
- Develop and improve work instructions, build sequences, tooling concepts, fixtures, and standardized assembly processes.
- Support engineering validation, qualification builds, ground testing, and flight-test campaigns.
- Design and fabricate custom brackets, tooling, fixtures, and prototype hardware.
- Identify opportunities to improve quality, efficiency, repeatability, and manufacturability.
- Mentor Prototype Technicians and establish strong technical, quality, and craftsmanship standards.
- Serve as a hands-on technical resource for complex manufacturing and assembly challenges.
Key Areas of Ownership
Prototype Manufacturing: Build complex aerospace hardware to demanding quality and schedule requirements.
Design for Manufacturability: Influence product design by bringing real-world manufacturing expertise into the engineering process.
Process Development: Create manufacturing methods that can evolve from one-off prototype builds into repeatable production processes.
Technical Leadership: Lead by example, solve difficult problems, and raise the technical capability of the prototype team.
Cross-Functional Collaboration: Work closely with Engineering, Manufacturing Engineering, Quality, and Production to keep development moving forward.
What Success Looks Like
- You consistently deliver complex prototype aircraft and hardware with exceptional quality.
- Manufacturing challenges are identified and solved before they become production problems.
- Engineering teams rely on your practical expertise to improve designs and buildability.
- Prototype processes become increasingly repeatable, efficient, and production-ready.
- Technicians become more capable through your mentorship and technical leadership.
- Your work directly accelerates the path from engineering concept to flight-ready and scalable aircraft.
Required Qualifications
- 10+ years of aerospace manufacturing, aircraft assembly, prototype, or related experience.
- Extensive experience with aircraft structural assembly and mechanical integration.
- Advanced composite manufacturing experience, including wet layup and structural repair.
- Experience supporting engineering development and first-article builds.
- Strong ability to interpret complex engineering drawings, CAD models, GD&T, and technical specifications.
- Demonstrated ability to troubleshoot complex manufacturing and assembly problems.
- Strong hands-on fabrication and mechanical assembly skills.
- Ability to obtain and maintain a U.S. Security Clearance.
Preferred Qualifications
- Experience with military aircraft, UAVs, UAS, eVTOL, rotorcraft, or other advanced aerospace platforms.
- Experience transitioning prototype hardware and processes into production.
- AS9100 or aerospace quality system experience.
- A&P License or equivalent aircraft maintenance qualification.
- Military aviation maintenance experience.
- Experience developing tooling, fixtures, or manufacturing processes.
- Previous experience leading, mentoring, or technically directing other technicians.
Why This Role Matters
This is an opportunity to do more than assemble aircraft. You will help define how the aircraft are built.
Every prototype is an opportunity to influence the next design, improve the manufacturing process, and establish the standards that enable production at scale. If you are an experienced aerospace technician who wants to have a direct impact on autonomous aircraft development while serving as a technical leader for the team, this role puts your expertise at the center of the mission.