Senior Propulsion Engineer
Shield AI
Other 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:
At Shield AI, we build intelligent aircraft that operate autonomously in the world’s most complex and high-threat environments. As a Senior Propulsion Engineer on our next-gen UAV program, you will be responsible for the development, integration, and early-stage validation of the platform’s propulsion system—from concept architecture to flight hardware.
You’ll lead propulsion subsystem design in collaboration with mechanical, thermal, and flight performance teams. This role focuses on hands-on design, modeling, and system-level decision-making in a fast-paced development environment. You’ll play a key part in defining how our next-gen platform achieves range, speed, endurance, and survivability.
We’re seeking a technically deep engineer who thrives in ambiguity, understands propulsion architecture holistically, and wants to push the boundaries of autonomous flight.
What you will do in this role:
- Lead the conceptual design and system architecture of a jet propulsion system for an unmanned aircraft
- Define key performance targets and constraints related to thrust, fuel consumption, heat rejection, and vibration
- Develop and analyze propulsion system requirements, control strategies, and failure modes
- Collaborate with the fuel, thermal, fluids, and mechanical design teams to ensure tight subsystem integration
- Evaluate and down select hardware (turbine engines, pumps, sensors, mounts, isolation systems) through trade studies and supplier engagement
- Conduct analytical modeling using MATLAB/Simulink, NPSS, and Thermal Desktop for system behavior under various flight regimes
- Author technical documents including requirements, FMEA, validation plans, and performance specs
- Participate in vehicle design reviews and lead propulsion-specific working groups
- Partner with test engineers to support prototype rig build-out, instrumentation plans, and performance validation
- Help transition propulsion designs from R&D to prototype and eventually to low-rate production
Required qualifications:
- Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field
- 8+ years of experience in propulsion system development, preferably for aerospace or UAVs
- Background in gas turbine propulsion, engine performance modeling, or system-level propulsion integration
- Experience using tools such as MATLAB/Simulink, Thermal Desktop, NPSS, or similar for analytical modeling
- Strong system-level thinking with an ability to translate vehicle goals into propulsion architecture
- Familiarity with CAD (e.g., Creo, NX) and ability to work closely with hardware designers
- Hands-on experience with propulsion hardware testing, data interpretation, and root cause analysis
- Excellent technical communication and cross-functional collaboration skills
Preferred qualifications:
- MS or PhD in Mechanical or Aerospace Engineering
- Experience on unmanned aerial systems (UAS) or fast-cycle defense aircraft development programs
- Familiarity with engine controls, embedded sensors, and thermal management
- Exposure to MIL-STD testing, DO-160, or qualification of flight-critical propulsion components
- Understanding of fuel system and thermal coupling
- Active or previous 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.