Staff Fuel Systems Engineer (R3300)
Shield AI
Software Engineering
Dallas County, TX, USA
Posted on Feb 11, 2025
About Shield AI
Founded in 2015, Shield AI is a venture-backed defense technology company focused on protecting service members and civilians with intelligent systems. Its flagship autonomy software, Hivemind, powers aircraft, drones, and other platforms, enabling complex missions with high reliability in contested environments. With offices in San Diego, Dallas, Washington, D.C., and internationally, Shield AI’s products actively support U.S. and allied operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn,Twitter, and Instagram.
Job Description:
Shield AI is seeking a Fuel Systems Engineer to lead the design, development, integration, and testing of advanced fuel systems for our next-generation AI-powered autonomous aircraft. This role will be instrumental in defining fuel storage, transfer, pressurization, and distribution systems that maximize aircraft endurance, efficiency, and mission readiness.
This is an opportunity to work on a cutting-edge UAV platform, similar to the V-BAT, that requires innovative fuel system solutions for long-endurance flight, efficient fuel consumption, and optimized center of gravity management. The ideal candidate has deep expertise in aircraft fuel system architecture, fluid dynamics, fuel system controls, and high-performance aerospace propulsion integration.
What you will do in this role:
- Lead the design and integration of advanced fuel systems to support autonomous aircraft operations in contested environments.
- Develop fuel storage, transfer, venting, and pressurization systems that optimize mission endurance and weight distribution.
- Design redundant and fail-safe fuel management architectures to enhance aircraft survivability and operational flexibility.
- Work closely with propulsion, avionics, structures, and thermal management teams to ensure seamless system integration.
- Conduct fluid dynamics modeling (CFD) and system-level simulations to optimize fuel flow efficiency and minimize pressure losses.
- Define fuel system performance parameters, including flow rate, pressure regulation, vapor suppression, and temperature stability.
- Oversee supplier selection, fuel system component qualification, and materials testing for aerospace-grade fuel tanks, pumps, valves, and sensors.
- Develop test procedures and verification strategies for ground-based and in-flight fuel system validation.
- Solve fuel system challenges, including altitude effects, cavitation, thermal expansion, and fuel slosh dynamics.
- Lead fuel system troubleshooting, failure analysis, and corrective action implementation during flight testing and operational deployments.
- Ensure compliance with FAA, MIL-STD, and aerospace industry fuel system regulations.
Required qualifications:
- Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or a related field.
- 10+ years in fuel systems engineering, aerospace fluid mechanics, and propulsion integration.
- Expertise in fuel storage, transfer, venting, and pressurization systems for high-performance aircraft or UAVs.
- Strong background in fluid dynamics, thermodynamics, and computational fluid dynamics (CFD).
- Proficiency in CFD tools (ANSYS Fluent, Open FOAM), MATLAB, Simulink, and CAD tools (CATIA, NX, SolidWorks).
- Experience with DO-160, MIL-STD-810, or similar aerospace fuel system certification requirements.
- Hands-on experience with fuel pumps, valves, fuel level sensors, and system integration testing.
- Strong troubleshooting and failure analysis skills for prototype and production fuel systems.
- US Citizenship required due to security clearance requirements.
Preferred qualifications:
- Experience working on military UAVs, fighter jets, or high-endurance ISR platforms.
- Background in low-observable (stealth) fuel system design and fuel vapor management.
- Knowledge of alternative fuel technologies, hybrid-electric propulsion, and energy storage systems.
- Prior experience supporting flight test operations, fuel consumption analysis, and mission endurance optimization.
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Total package details for U.S. based positions:
- Regular employee positions: Salary within range listed above + Bonus + Benefits + Equity
- Temporary employee positions: Hourly within range listed above + temporary benefits package (applicable after 60 days
of employment)
- Interns/Military Fellows/Part-time not eligible for bonus, benefits or equity
Total package details for International positions which are roles based outside of the United States (where applicable):
- International premium, hardship differential, cost of living differential, living quarters allowance, foreign service transfer
allowance, equity, international benefits, visa assistance, and relocation assistance.
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.
Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.