Lead Fuel Systems Engineer (Dallas)
Shield AI
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Dallas County, TX, USA
Posted on Mar 20, 2025
Founded in 2015, Shield AI is a venture-backed defense technology company with the mission of protecting service members and civilians with intelligent, autonomous systems. Its products include Hivemind Enterprise—EdgeOS, Pilot, Commander, and Forge—as well as V-BAT and Sentient Vision Systems (wide-area motion imaging software). With offices in San Diego, Dallas, Washington, D.C., Abu Dhabi (UAE), Kyiv (Ukraine), and Melbourne (Australia), Shield AI’s technology actively supports U.S. and allied operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X and Instagram.
Job Description:
At Shield AI, we're building the most intelligent autonomous aircraft ever deployed. As we push the boundaries of what’s possible in contested environments, we’re looking for a Lead Fuel Systems Engineer to drive the design, development, and integration of cutting-edge fuel systems that push the limits of endurance and performance.
In this role, you’ll be at the forefront of developing mission-critical fuel solutions for our next generation advanced UAV platform, ensuring seamless fuel storage, transfer, and pressurization for long-endurance, high-performance autonomous flight. You’ll work alongside top-tier engineers in propulsion, avionics, structures, and AI to create game-changing fuel systems that enhance survivability, efficiency, and operational flexibility in contested environments.
This is more than just a job it’s a chance to redefine what’s possible in autonomous aviation.
What you will do in this role:
- Lead the design and integration of advanced fuel systems for autonomous aircraft in high-stakes missions.
- Optimize mission endurance and weight distribution through innovative fuel storage, transfer, venting, and pressurization solutions.
- Architect fail-safe, redundant fuel management systems to ensure operational flexibility and survivability.
- Collaborate cross-functionally with propulsion, avionics, thermal, and structures teams for seamless system integration.
- Apply CFD and system-level modeling to optimize fuel flow, minimize pressure losses, and enhance thermal stability.
- Oversee supplier selection, component qualification, and aerospace-grade fuel system testing.
- Solve real-world challenges like cavitation, thermal expansion, and high-altitude fuel behavior.
- Support fuel system testing, troubleshooting, and performance analysis for flight validation.
- Ensure compliance with FAA, MIL-STD, and aerospace fuel system regulations.
Required qualifications:
- 8 + years of experience in aerospace fuel systems engineering, fluid mechanics, and propulsion integration.
- Deep expertise in fuel storage, transfer, pressurization, and venting systems for high-performance aircraft or UAVs.
- Strong background in fluid dynamics, thermodynamics, and computational fluid dynamics (CFD).
- Proficiency in CFD tools (ANSYS Fluent, OpenFOAM), MATLAB, Simulink, and CAD (CATIA, NX, SolidWorks).
- Experience with DO-160, MIL-STD-810, or other aerospace fuel system certification standards.
- Hands-on knowledge of fuel pumps, valves, sensors, and system integration testing.
- Strong troubleshooting and problem-solving skills for prototype and production fuel systems.
- US Citizenship required due to security clearance requirements.
Preferred qualifications:
- Experience with military UAVs, fighter jets, or high-endurance ISR platforms.
- Background in stealth fuel system design and vapor management.
- Knowledge of alternative fuel technologies, hybrid-electric propulsion, and advanced energy storage.
- Experience supporting flight test operations and mission endurance optimization.
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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.
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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.
This job is no longer accepting applications
See open jobs at Shield AI.See open jobs similar to "Lead Fuel Systems Engineer (Dallas)" Homebrew.