Principal Fuel Systems Engineer
Shield AI
Software Engineering
Dallas County, TX, USA
Posted on Jun 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:
Shield AI is building the world’s most advanced AI pilot to enable intelligent aircraft to operate autonomously in denied environments. As the Principal Fuel Systems Engineer on our next-gen program, you’ll be the technical authority responsible for the architecture, integration, and long-term evolution of fuel systems across the platform.
You will lead all aspects of fuel system development—from early R&D and trade studies to full-rate production readiness. This role combines deep technical fluency with system-level thinking and leadership. You'll partner with cross-functional teams to develop reliable, efficient, and lightweight fuel subsystems capable of supporting long-range autonomous missions in contested environments.
We are looking for a hands-on technical leader with a strong record of delivery in complex propulsion systems who can drive the vision for how fuel is stored, moved, and managed across a next-generation jet-powered aircraft.
What you will do in this role:
- Serve as the technical lead for fuel systems across the next-gen platform, from concept through production
- Architect the fuel storage, delivery, pressurization, and regulation systems, with full ownership of requirements and performance metrics
- Lead early-phase trade studies, system architecture evaluations, and supplier assessments for fuel-related components (tanks, pumps, regulators, valves, etc.)
- Develop and validate flow models, transient behavior, and thermal interactions using tools like MATLAB/Simulink, Thermal Desktop, and ANSYS
- Oversee component-level design and packaging decisions in collaboration with mechanical, thermal, and propulsion integration teams
- Ensure system compliance with mission, safety, and redundancy requirements; conduct and review FMEAs, hazard analyses, and fault trees
- Lead and mentor a team of fuel and fluid engineers, providing technical direction and career development support
- Guide the test strategy and validation roadmap, including prototype development, instrumentation planning, and data analysis
- Influence long-term system evolution, including modularity, serviceability, and scaling across vehicle variants
- Represent the fuel system in high-level design reviews, program risk assessments, and cross-discipline working groups
Required qualifications:
- Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related field
- 15+ years of experience in fuel systems engineering for aerospace or high-reliability applications
- Demonstrated experience owning the full lifecycle of flight-critical fuel systems—from clean sheet design to test and integration
- Deep knowledge of fuel dynamics, thermal effects, pressurization systems, and component-level performance
- Proficiency in relevant tools including MATLAB/Simulink, Thermal Desktop, and CAD software (e.g. Creo or NX)
- Strong experience with design for safety, regulatory compliance, and aerospace qualification standards
- Experience mentoring engineers and driving technical strategy across departments
- Excellent technical writing, communication, and leadership skills
Preferred qualifications:
- MS or PhD in Mechanical or Aerospace Engineering
- Experience with turbine-powered aircraft, UAVs, or military jet platforms
- Familiarity with MIL-STD-810, DO-160, or fuel qualification standards for aerospace
- Background in flight test instrumentation, fuel sensors, or system-level telemetry
- Active or prior DoD clearance (not required)
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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.