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Lead Fuel Systems Engineer

Lead Fuel Systems Engineer

CompanyShield AI
LocationDallas, TX, USA
Salary$141305 – $252714
TypeFull-Time
Degrees
Experience LevelExpert or higher

Requirements

  • 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.

Responsibilities

  • 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.

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.