Job Description:Shield AI is seeking a Principal Fuel Systems Engineer to lead architecture, development, and validation of fuel systems for advanced AI-powered aircraft. In this role, you'll own the full lifecycle of fuel system design-from concept through flight testing-while mentoring others and driving technical excellence across our growing air vehicle portfolio.
You'll tackle high-impact challenges: enabling efficient long-endurance flight, optimizing aircraft center of gravity, and developing robust, certifiable systems that perform flawlessly in extreme conditions.
On-site or hybrid work is preferred; however, for highly qualified candidates, a remote arrangement may be considered with up to 25% travel.
What you will do in this role: - Architect end-to-end fuel systems including storage, transfer, venting, and pressurization for next-gen autonomous aircraft.
- Lead cross-functional integration between propulsion, structures, avionics, and thermal teams to ensure optimal system performance.
- Conduct system-level modeling and analysis to predict flow behavior, vapor suppression, slosh dynamics, and thermal effects.
- Define performance requirements and verification strategies for high-reliability components and assemblies.
- Lead design reviews, technical trade studies, and risk assessments for critical systems.
- Oversee supplier selection, qualification, and acceptance testing for pumps, valves, tanks, and sensors.
- Support and guide ground and flight test campaigns; perform root-cause analysis for system anomalies.
- Mentor engineers, establish best practices, and develop processes for system integration and testing.
- Contribute to long-term technology roadmaps, including hybrid-electric and alternative fuel system architectures.
Required qualifications: - B.S. or M.S. in Aerospace, Mechanical, or related engineering discipline.
- 12-15+ years of experience in aircraft fuel systems, aerospace fluids, or propulsion integration.
- Demonstrated expertise with fuel system design, analysis, and certification for manned or unmanned aircraft.
- Deep understanding of fluid mechanics, thermodynamics, and CFD principles.
- Proficiency with analysis and modeling tools (ANSYS Fluent, OpenFOAM, MATLAB/Simulink) and CAD software (NX, CATIA, or SolidWorks).
- Strong technical leadership and mentoring experience within multidisciplinary teams.
- Familiarity with FAA and MIL-STD certification requirements and validation testing.
- U.S. Citizenship required.
- For remote candidates - ability to travel up to 25%.
- Ability to obtain a S//SAR level security clearance desired.
Preferred qualifications: - Experience with UAV, fighter, or ISR platform development.
- Proven success leading complex fuel system programs from concept through flight test.
- Knowledge of advanced or low-observable fuel system technologies, vapor suppression, and hybrid-electric integration.
- Active or previous security clearance.
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Full-time regular employee offer package:
Pay within range listed + Bonus + Benefits + Equity
Temporary employee offer package:
Pay within range listed above + temporary benefits package (applicable after 60 days of employment)
Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location. All offers are contingent on a cleared background and possible reference check. Military fellows and part-time employees are not eligible for benefits. Please speak to your talent acquisition representative for more information.
