Staff Fuel Systems Engineer

Shield AI is seeking a Fuel Systems Engineer to lead the design, development, integration, and testing of advanced fuel systems for our next-generation AI-powered autonomous aircraft. This role will be instrumental in defining fuel storage, transfer, pressurization, and distribution systems that maximize aircraft endurance, efficiency, and mission readiness.

This is an opportunity to work on a cutting-edge UAV platform, similar to the V-BAT, that requires innovative fuel system solutions for long-endurance flight, efficient fuel consumption, and optimized center of gravity management. The ideal candidate has deep expertise in aircraft fuel system architecture, fluid dynamics, fuel system controls, and high-performance aerospace propulsion integration.

What you will do in this role:

• Lead the design and integration of advanced fuel systems to support autonomous aircraft operations in contested environments.
• Develop fuel storage, transfer, venting, and pressurization systems that optimize mission endurance and weight distribution.
• Design redundant and fail-safe fuel management architectures to enhance aircraft survivability and operational flexibility.
• Work closely with propulsion, avionics, structures, and thermal management teams to ensure seamless system integration.
• Conduct fluid dynamics modeling (CFD) and system-level simulations to optimize fuel flow efficiency and minimize pressure losses.
• Define fuel system performance parameters, including flow rate, pressure regulation, vapor suppression, and temperature stability.
• Oversee supplier selection, fuel system component qualification, and materials testing for aerospace-grade fuel tanks, pumps, valves, and sensors.
• Develop test procedures and verification strategies for ground-based and in-flight fuel system validation.
• Solve fuel system challenges, including altitude effects, cavitation, thermal expansion, and fuel slosh dynamics.
• Lead fuel system troubleshooting, failure analysis, and corrective action implementation during flight testing and operational deployments.
• Ensure compliance with FAA, MIL-STD, and aerospace industry fuel system regulations.

Required qualifications:

• Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or a related field.
• 10+ years in fuel systems engineering, aerospace fluid mechanics, and propulsion integration.
• Expertise in fuel storage, transfer, venting, and pressurization systems for high-performance aircraft or UAVs.
• Strong background in fluid dynamics, thermodynamics, and computational fluid dynamics (CFD).
• Proficiency in CFD tools (ANSYS Fluent, Open FOAM), MATLAB, Simulink, and CAD tools (CATIA, NX, SolidWorks).
• Experience with DO-160, MIL-STD-810, or similar aerospace fuel system certification requirements.
• Hands-on experience with fuel pumps, valves, fuel level sensors, and system integration testing.
• Strong troubleshooting and failure analysis skills for prototype and production fuel systems.
• US Citizenship required due to security clearance requirements.

Preferred qualifications:

• Experience working on military UAVs, fighter jets, or high-endurance ISR platforms.
• Background in low-observable (stealth) fuel system design and fuel vapor management.
• Knowledge of alternative fuel technologies, hybrid-electric propulsion, and energy storage systems.
• Prior experience supporting flight test operations, fuel consumption analysis, and mission endurance optimization.