Senior Engineer Propulsion - Engine Performance (R5907)

Shield AI; Dallas, Northern (TX, KY); On-site; USD 117,000 - 176,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

Shield AI is seeking a Propulsion Performance Engineer to own engine calibration and performance for the V-BAT platform. You will drive test plans, ECU tuning, and performance analysis from bench through flight test, shaping torque, power, speed, and fuel efficiency across the operating envelope.

You will work hands-on with reciprocating engines and fuel injection systems, develop calibration documentation, and collaborate with design, controls, and flight test teams to meet program milestones.

Qualifications

• Bachelor's degree in Mechanical or Aerospace Engineering.
• 5+ years in mechanical or aerospace engineering focusing on engine performance or calibration.
• Hands-on experience with reciprocating engines.
• Experience with ECU configuration and engine calibration.
• Proven ability to analyze engine torque, power, and fuel consumption data.

Responsibilities

• Define test plans and calibration methodology for dynamometer, bench, and flight tests.
• Tune ECU including fuel mapping, ignition timing, and injector phasing.
• Analyze torque, power, and fuel consumption data to drive design and calibration decisions.
• Lead root-cause investigations for engine testing.
• Create and maintain calibration documentation and performance reports.
• Collaborate with design, controls, and flight test teams in reviews.

Skills

Engine calibration

ECU tuning

Data analysis

Reciprocating engines

Python/MATLAB

Dynamometer testing

ITAR compliance

Education

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Aerospace Engineering

MS/PhD in Mechanical/Aerospace Engineering

Tools

Python

MATLAB

Data acquisition systems

Job description

Shield AI is a venture-backed defense-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software, V-BAT and X-BATaircraft, and Aechelon simulation and synthetic reality technologies. With offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific, Shield AI's technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description:

We are seeking a Propulsion Performance Engineer to own engine calibration and performance for the reciprocating engines that power the V-BAT platform. This role serves as the technical owner for engine calibration strategy - driving test plans, ECU tuning, and performance analysis from bench through flight test - and is accountable for the torque, power, speed, and fuel efficiency characteristics the engine delivers across its full operating envelope. You'll work hands-on with engine hardware, electronic fuel injection and engine control systems, and engine test stands, creating and executing engine testing strategies under the direction of senior staff propulsion engineers.

What You'll Do In This Role

• Support the engine calibration strategy by defining test plans, calibration methodology, and acceptance criteria across dynamometer, bench, and flight test campaigns.
• Perform ECU configuration and tuning (including fuel mapping, ignition timing, and injector phasing) to optimize engine performance, fuel efficiency, and reliability across the operating envelope.
• Analyze and deliver torque, power, and fuel consumption results, identifying calibration or hardware improvement opportunities and driving corrective action.
• Lead troubleshooting and root-cause investigations for engine testing for the development team and production teams.
• Reduce and interpret test and flight data to validate performance against requirements, closing gaps between design intent and measured behavior.
• Represent engine calibration and performance in design reviews, technical readiness checkpoints, and cross-functional discussions with design, controls, and flight test teams.
• Develop and maintain calibration documentation, procedures, and performance reporting to support program milestones.
• Support refinement of performance models for the propulsion system and the vehicle through targeted test campaigns and data review.

Required qualifications:

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.
• 5+ years of experience in a mechanical or aerospace engineering role, with a focus on engine performance or calibration.
• Deep hands-on experience with reciprocating (piston) engines.
• Demonstrated experience with electronically controlled fuel injectors and fuel injection systems.
• Proven experience with ECU configuration and engine calibration, including ownership of calibration decisions.
• Strong ability to analyze and interpret engine torque, power, and fuel consumption data to drive engine design, ECU calibration, and vehicle performance decisions.
• U.S. Citizenship or ability to comply with ITAR requirements.

Preferred qualifications:

• Podium finish in FSAE competition, with at least one first place trophy in any dynamic event.
• Background in air-cooled engines, particularly aviation two-stroke platforms.
• Experience with dynamometer test cells and associated data acquisition systems.
• Deep familiarity with fuel maps, ignition timing strategies, and closed-loop engine control logic.
• Proficiency in Python or MATLAB for data reduction and calibration tooling.
• Experience writing custom data analysis tools to automate engine performance analysis and calibration workflows.
• Experience supporting military propulsion systems, tactical aircraft, or high-performance aerospace platforms.
• M.S. or Ph.D. in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.

$117,000 - $176,000 a year

Full-time regular employee offer package:

Pay within range listed + Bonus + Benefits + Equity

Temporary employee offer package:

Pay within range listed above + temporary benefits package (applicable after 60 days of employment)

Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location. All offers are contingent on a cleared background and possible reference check. Military fellows and part-time employees are not eligible for benefits. Please speak to your talent acquisition representative for more information.

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed toequal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.