Principal Fuel Systems Engineer (X-BAT)

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.

• 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.

• 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.

• U.S. Citizenship required.

• For remote candidates - ability to travel up to 25%.

• 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.

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.

Founded in 2015, 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 and V-BAT and X-BAT aircraft. 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 .