Staff Engineer, Fuel Systems (R5900)

f7d8749a-72d6-407c-bf98-292ea630c73a•Dallas, TX

About The Position

Shield AI is seeking a highly motivated Staff Fuel System Engineer to support the design, development, integration, and fielding of a next-generation autonomous aircraft system. The role balances technical rigor, rapid decision-making, and hands-on engineering to transition concepts into operational capability in an accelerated aircraft development environment. The engineer will serve as the Responsible Engineer for the aircraft fuel system, owning technical execution from requirements and architecture through design, procurement, integration, build, test, flight, and operational support. The role calls for strong thermofluid fundamentals and engineering judgment, plus the ability to understand fuel-system behavior across demanding aircraft operating conditions and act as the focal point among propulsion, vehicle teams, suppliers, and flight operations.

Requirements

Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or a related engineering discipline.
7+ years of experience in aerospace fuel systems, fluid systems, propulsion, or related aircraft system development, with demonstrated ownership of complex aerospace hardware.
Strong understanding of thermodynamics, fluid mechanics, heat transfer, and compressible and incompressible flow.
Strong understanding of aerospace fuel-system design, including pressure losses, pump performance, venting, vapor pressure, cavitation, transient flow behavior, and thermal effects.
Hands-on experience with fluid-system hardware integration, instrumentation, testing, flight support, and technical failure investigations.
Strong proficiency in Python or similar tools for engineering analysis, data reduction, and model correlation.
Demonstrated ability to independently drive ambiguous technical problems to measurable results in a fast-paced development environment.
U.S. citizenship and an active security clearance.

Nice To Haves

Experience developing fuel systems for high-performance aircraft, tactical aircraft, UAVs, or similar aerospace platforms.
Experience designing fuel systems for elevated-G maneuvering, aggressive vehicle dynamics, or challenging fuel-delivery conditions.
Experience with fuel tanks, pumps, valves, regulators, level sensing, venting, pressurization, and fuel-system control hardware.
Familiarity with GFSSP, REFPROP, CFD, ANSYS, FEA, or similar thermal-fluid analysis tools.
Experience working with aerospace suppliers through component selection, procurement, development, qualification, and integration.
Background in rocket propulsion or propellant systems with experience transferable to aerospace fuel-system design, analysis, integration, or test.
M.S. or Ph.D. in Aerospace Engineering, Mechanical Engineering, or a related engineering discipline.

Responsibilities

Serve as the Responsible Engineer for the aircraft fuel system, owning requirements, architecture, interfaces, hardware, and technical decisions from concept through operational deployment.
Design, size, and integrate fuel tanks, pumps, valves, plumbing, venting and pressurization systems, filtration, level sensing, and associated fuel-system hardware.
Analyze fuel-system performance across the aircraft operating envelope, including pressure and flow requirements, transient engine demand, elevated-G maneuvering, tank depletion, slosh, vapor pressure, cavitation, vapor ingestion, and thermal effects.
Lead technical design reviews, supplier engagements, and hardware procurement, ensuring the fuel system meets performance, mass, thermal, reliability, safety, and mission requirements.
Plan and execute component, subsystem, and vehicle-level testing, including instrumentation, procedures, data acquisition, performance validation, and flight readiness.
Analyze ground and flight data to validate system performance, quantify margin, identify anomalies, and drive hardware or operational improvements.
Lead failure investigations and root-cause efforts using analysis, inspection, testing, and data to develop effective corrective actions.
Work hands-on with design engineers, technicians, propulsion, controls, airframe, manufacturing, supply chain, test, and flight teams to build, integrate, troubleshoot, and iterate flight hardware.