Principal Fuel Systems Engineer (X-BAT)

Job Description: Shield AI is seeking a Principal Fuel Systems Engineer to lead architecture, development, and validation of fuel systems for advanced AI-powered aircraft. In this role, you’ll own the full lifecycle of fuel system design—from concept through flight testing—while mentoring others and driving technical excellence across our growing air vehicle portfolio.

You’ll tackle high-impact challenges: enabling efficient long-endurance flight, optimizing aircraft center of gravity, and developing robust, certifiable systems that perform flawlessly in extreme conditions.

On-site or hybrid work is preferred; however, for highly qualified candidates, a remote arrangement may be considered with up to 25% travel.

Job Description: Shield AI is seeking a Principal Fuel Systems Engineer to lead architecture, development, and validation of fuel systems for advanced AI-powered aircraft. In this role, you’ll own the full lifecycle of fuel system design—from concept through flight testing—while mentoring others and driving technical excellence across our growing air vehicle portfolio.

You’ll tackle high-impact challenges: enabling efficient long-endurance flight, optimizing aircraft center of gravity, and developing robust, certifiable systems that perform flawlessly in extreme conditions.

On-site or hybrid work is preferred; however, for highly qualified candidates, a remote arrangement may be considered with up to 25% travel.

• B.S. or M.S. in Aerospace, Mechanical, or related engineering discipline.

• 12–15+ years of experience in aircraft fuel systems, aerospace fluids, or propulsion integration.

• Demonstrated expertise with fuel system design, analysis, and certification for manned or unmanned aircraft.

• Deep understanding of fluid mechanics, thermodynamics, and CFD principles.

• Proficiency with analysis and modeling tools (ANSYS Fluent, OpenFOAM, MATLAB/Simulink) and CAD software (NX, CATIA, or SolidWorks).

• Strong technical leadership and mentoring experience within multidisciplinary teams.

• Familiarity with FAA and MIL-STD certification requirements and validation testing.

• Ability to obtain a S//SAR level security clearance desired.
• Experience with UAV, fighter, or ISR platform development.

• Proven success leading complex fuel system programs from concept through flight test.

• Knowledge of advanced or low-observable fuel system technologies, vapor suppression, and hybrid-electric integration.

• Active or previous security clearance.
• Architect end-to-end fuel systems including storage, transfer, venting, and pressurization for next-gen autonomous aircraft.

• Lead cross-functional integration between propulsion, structures, avionics, and thermal teams to ensure optimal system performance.

• Conduct system-level modeling and analysis to predict flow behavior, vapor suppression, slosh dynamics, and thermal effects.

• Define performance requirements and verification strategies for high-reliability components and assemblies.

• Lead design reviews, technical trade studies, and risk assessments for critical systems.

• Oversee supplier selection, qualification, and acceptance testing for pumps, valves, tanks, and sensors.

• Support and guide ground and flight test campaigns; perform root-cause analysis for system anomalies.

• Mentor engineers, establish best practices, and develop processes for system integration and testing.

• Contribute to long-term technology roadmaps, including hybrid-electric and alternative fuel system architectures.