Lead Fuel Systems Engineer (R3300)

As a Lead Fuel Systems Engineer at Shield AI, you will be responsible for the design and integration of advanced fuel systems for autonomous aircraft. This includes optimizing fuel storage and transfer solutions, architecting fail-safe management systems, and collaborating cross-functionally with other engineering teams. Your role is critical in solving real-world challenges associated with fuel behavior in high-altitude missions, ensuring that our UAVs operate with maximum efficiency and reliability.

To qualify for the Lead Fuel Systems Engineer position at Shield AI, candidates should possess over eight years of experience in aerospace fuel systems engineering, fluid mechanics, and propulsion integration. Expertise in fuel storage and transfer systems for high-performance aircraft is essential, along with a strong background in fluid dynamics, thermodynamics, and computational fluid dynamics (CFD). Proficiency in relevant tools such as MATLAB, Simulink, and CAD software is also required.

At Shield AI, compliance with aviation regulations such as FAA and MIL-STD is paramount, particularly for the Lead Fuel Systems Engineer role. You will oversee and verify that all fuel systems meet stringent regulatory standards through careful testing, validation, and qualification processes. Your expertise in certification standards will play a key role in ensuring the safety and reliability of our UAV platforms.

The work culture at Shield AI is innovative, collaborative, and driven by a shared mission to redefine autonomous aviation. As a Lead Fuel Systems Engineer, you will be part of a dynamic team of experts who encourage creativity, problem-solving, and pushing the boundaries of technology. You'll engage with cross-functional teams, fostering an environment where everyone’s expertise contributes to our overarching goal of enhancing safety and performance in aviation.

At Shield AI, we are committed to the professional growth of our employees, especially for Lead Fuel Systems Engineers. With a solid foundation in advanced aerospace technology and collaboration across departments, there are ample opportunities for you to step into roles that drive innovation and influence company strategy. Our supportive environment and focus on teamwork ensure that your career path can be tailored to your strengths and aspirations.

When answering this question, emphasize your hands-on experience with various fuel systems, focusing on specific projects that illustrate your depth of knowledge and skills. Discuss the design and analysis processes you've led, and mention how these experiences have prepared you for the challenges at Shield AI.

In your response, detail the methods you've used to optimize fuel flow, such as employing computational fluid dynamics (CFD) modeling or adjusting system parameters. Highlight specific tools and techniques you've successfully implemented in past projects and the results of those efforts.

When discussing a challenge, frame the situation clearly and describe the technical complexities you encountered. Explain the steps you took to address the issue, what solutions you implemented, and how it ultimately contributed to a successful project outcome.

In your answer, demonstrate an understanding of key regulations such as DO-160 and MIL-STD. Discuss how these regulations impact design decisions and testing processes in your previous roles, showcasing your ability to navigate compliance while maintaining innovation.

Describe your approach to teamwork, emphasizing the importance of clear communication and respect for each discipline’s expertise. Share examples of successful collaborations in the past and how these experiences have shaped your ability to work effectively in diverse teams.

Explain how you utilize computational fluid dynamics (CFD) in your designs. Discuss specific tools such as ANSYS Fluent or OpenFOAM and mention some successful applications of CFD in your previous work to enhance fuel flow and thermal stability.

Outline your troubleshooting process, focusing on how you diagnose issues through testing and analysis. Give examples of tools you use and how you work to identify root causes, implement solutions, and validate results in a systematic way.

Discuss specific projects or roles where you worked with high-endurance UAVs or military aircraft, highlighting the unique challenges these platforms present. Emphasize your contributions and any notable achievements that demonstrate your capability to work in demanding environments.

Share your strategies for ensuring reliability, such as rigorous testing protocols, risk assessment, and fail-safe designs. Explain how you incorporate these practices into your development processes to ensure safety and operational efficacy.

Express your interest in emerging technologies and innovations that could affect fuel systems, such as alternative fuels or advanced energy storage solutions. Discuss how these trends can enhance the designs and performance of modern autonomous aircraft.