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Shield AI, a venture-backed defense-tech company, is seeking a Staff Fuel Systems Engineer to own the design, development, integration, and fielding of fuel systems for next-generation autonomous aircraft. This is a Responsible Engineer (RE) role with end-to-end technical ownership from requirements and architecture through design, procurement, integration, build, test, flight, and operational support.
You will drive fuel system technical execution across the full aircraft operating envelope, including pressure and flow analysis, transient engine demand, elevated-G maneuvering, tank depletion, slosh dynamics, vapor pressure, cavitation, and thermal effects. Key responsibilities include designing and sizing fuel tanks, pumps, valves, plumbing, venting, pressurization, filtration, and level sensing systems; leading technical design reviews and supplier engagements; planning and executing component, subsystem, and vehicle-level testing; analyzing ground and flight data to validate performance and identify anomalies; leading failure investigations and root cause analysis; and working hands-on with design engineers, technicians, propulsion, controls, airframe, manufacturing, supply chain, test, and flight teams.
This role requires strong thermofluid fundamentals, engineering judgment, rapid decision-making, and the ability to balance technical rigor with accelerated development timelines. You will serve as the focal point between propulsion, vehicle teams, suppliers, and flight operations, taking ownership of complex problems and driving meaningful capability into the hands of operators quickly.
REQUIREMENTS:
- Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related engineering discipline
- 7+ years of experience in aerospace fuel systems, fluid systems, propulsion, or related aircraft system development with demonstrated ownership of complex aerospace hardware
- Strong understanding of thermodynamics, fluid mechanics, heat transfer, and compressible/incompressible flow
- Strong understanding of aerospace fuel system design, including pressure losses, pump performance, venting, vapor pressure, cavitation, transient flow behavior, and thermal effects
- Hands-on experience with fluid system hardware integration, instrumentation, testing, flight support, and technical failure investigations
- Strong proficiency in Python or similar tools for engineering analysis, data reduction, and model correlation
- Demonstrated ability to independently drive ambiguous technical problems to measurable results in fast-paced development environment
- U.S. Citizenship and active security clearance
PREFERRED QUALIFICATIONS:
- Experience developing fuel systems for high-performance aircraft, tactical aircraft, UAVs, or similar aerospace platforms
- Experience designing fuel systems for elevated-G maneuvering, aggressive vehicle dynamics, or challenging fuel delivery conditions
- Experience with fuel tanks, pumps, valves, regulators, level sensing, venting, pressurization, and fuel system control hardware
- Familiarity with GFSSP, REFPROP, CFD, ANSYS, FEA, or similar thermal-fluid analysis tools
- Experience working with aerospace suppliers through component selection, procurement, development, qualification, and integration
- Background in rocket propulsion or propellant systems with transferable experience to aerospace fuel system design, analysis, integration, or test
- M.S. or Ph.D. in Aerospace Engineering, Mechanical Engineering, or related engineering discipline
