Lead Fuel Systems Engineer (R3300)

Shield AI; Dallas (TX); On-site; USD 141,000 - 253,000; Full time

Job summary

Join a leading defense technology company as a Lead Fuel Systems Engineer. Drive the design and integration of advanced fuel systems for autonomous aircraft, ensuring optimal performance in high-stakes missions. Collaborate with top engineers to enhance operational flexibility and survivability. This role offers a unique opportunity to redefine autonomous aviation with cutting-edge technology.

Benefits

Bonus

Benefits

Equity for full-time employees

Qualifications

• 8+ years of experience in aerospace fuel systems engineering.
• Deep expertise in fuel storage, transfer, and pressurization systems.

Responsibilities

• Lead design and integration of advanced fuel systems for UAVs.
• Collaborate with cross-functional teams for seamless integration.
• Ensure compliance with FAA and MIL-STD regulations.

Skills

Fluid Mechanics

Problem Solving

Troubleshooting

Tools

ANSYS Fluent

MATLAB

Simulink

CATIA

NX

SolidWorks

Job description

Join to apply for the Lead Fuel Systems Engineer (R3300) role at Shield AI

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:**
Shield AI is on a mission to build the world’s most advanced AI pilots for next-generation autonomous aircraft, and we’re looking for a Lead Fuel Systems Engineer to drive the design, development, and integration of cutting-edge fuel systems that push the limits of endurance and performance.

In this role, you’ll be at the forefront of developing mission-critical fuel solutions for our next generation advanced UAV platform, ensuring seamless fuel storage, transfer, and pressurization for long-endurance, high-performance autonomous flight. You’ll work alongside top-tier engineers in propulsion, avionics, structures, and AI to create game-changing fuel systems that enhance survivability, efficiency, and operational flexibility in contested environments.

This is more than just a job—it’s a chance to redefine what’s possible in autonomous aviation.

**What you will do in this role:**

• Lead the design and integration of advanced fuel systems for autonomous aircraft in high-stakes missions.
• Optimize mission endurance and weight distribution through innovative fuel storage, transfer, venting, and pressurization solutions.
• Architect fail-safe, redundant fuel management systems to ensure operational flexibility and survivability.
• Collaborate cross-functionally with propulsion, avionics, thermal, and structures teams for seamless system integration.
• Apply CFD and system-level modeling to optimize fuel flow, minimize pressure losses, and enhance thermal stability.
• Oversee supplier selection, component qualification, and aerospace-grade fuel system testing.
• Solve real-world challenges like cavitation, thermal expansion, and high-altitude fuel behavior.
• Support fuel system testing, troubleshooting, and performance analysis for flight validation.
• Ensure compliance with FAA, MIL-STD, and aerospace fuel system regulations.

**Required qualifications:**

• 8+ years of experience in aerospace fuel systems engineering, fluid mechanics, and propulsion integration.
• Deep expertise in fuel storage, transfer, pressurization, and venting systems for high-performance aircraft or UAVs.
• Strong background in fluid dynamics, thermodynamics, and computational fluid dynamics (CFD).
• Proficiency in CFD tools (ANSYS Fluent, OpenFOAM), MATLAB, Simulink, and CAD (CATIA, NX, SolidWorks).
• Experience with DO-160, MIL-STD-810, or other aerospace fuel system certification standards.
• Hands-on knowledge of fuel pumps, valves, sensors, and system integration testing.
• Strong troubleshooting and problem-solving skills for prototype and production fuel systems.
• US Citizenship required due to security clearance requirements.

**Preferred qualifications:**

• Experience with military UAVs, fighter jets, or high-endurance ISR platforms.
• Background in stealth fuel system design and vapor management.
• Knowledge of alternative fuel technologies, hybrid-electric propulsion, and advanced energy storage.
• Experience supporting flight test operations and mission endurance optimization.

Salary range: $141,305 - $252,714 annually. The final role scope and level will be determined during the interview process.

**Benefits:** Pay within the listed range, bonus, benefits, and equity for full-time employees; temporary benefits for temporary employees after 60 days.

Shield AI is an equal opportunity employer, committed to diversity and inclusion. Accommodations available for disabilities or needs.

**Additional details:**
- Seniority level: Mid-Senior level
- Employment type: Full-time
- Job function: Information Technology
- Industry: Software Development

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