Principal Fuel Systems Engineer - X-BAT (R4640)

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.