Staff Fuel Systems Engineer

Job Description:

Shield AI is seeking a Staff Fuel Systems Engineer to design, analyze, and integrate fuel systems for our next-generation autonomous aircraft. You’ll help develop innovative fuel storage, transfer, and distribution systems that improve endurance, efficiency, and reliability in challenging operational environments.

This role is ideal for an engineer eager to take ownership of complex subsystems, collaborate across disciplines, and grow into a technical leader working at the intersection of autonomy, flight science, and fluid systems.

What you will do in this role:

• Design and develop fuel storage, transfer, and venting systems to support high-performance, long-endurance UAVs.
• Perform fluid and thermal analysis to optimize flow efficiency, pressure regulation, and system mass.
• Support integration of fuel systems with propulsion, avionics, and thermal management teams.
• Conduct CFD simulations, bench-level testing, and validation of pumps, valves, sensors, and tanks.
• Generate design documentation, system schematics, and verification plans to support engineering reviews and flight test readiness.
• Assist in supplier coordination, component selection, and qualification testing.
• Troubleshoot fuel system issues during prototype builds and flight test campaigns.
• Contribute to the development of system architecture and help mature design standards across new programs.

Required qualifications:

• B.S. or M.S. in Aerospace, Mechanical, or related engineering discipline.
• 4-7 years of experience in fuel or fluid systems design, analysis, or integration.
• Working knowledge of CFD and thermal/fluid simulation tools (ANSYS Fluent, OpenFOAM, MATLAB/Simulink).
• Experience with pumps, valves, and sensors for fuel or hydraulic systems.
• Familiarity with aerospace environmental and certification standards (e.g., DO-160, MIL-STD-810).
• Excellent communication and collaboration skills in fast-paced, cross-functional environments.
• U.S. Citizenship required.
• Ability to obtain a S//SAR level security clearance desired.

Preferred qualifications:

• Experience supporting UAV, fighter, or propulsion system integration.
• Hands-on experience with prototype build, test, and troubleshooting.
• Familiarity with CATIA, NX, or SolidWorks for CAD design and modeling.
• Exposure to mission endurance optimization and energy management strategies.