We are seeking a Senior Propulsion Test Engineer to lead the planning and execution of propulsion test campaigns for the X-BAT platform. This role is responsible for end-to-end ownership of propulsion test activities—from test architecture and test stand design through execution, data analysis, and iteration - supporting a low-bypass turbofan-powered Group 5 UAV.
You will serve as the focal point for propulsion testing, ensuring test results accurately characterize engine and subsystem performance, de-risk integration, and inform flight readiness decisions. This role is hands-on, data-driven, and highly cross-functional - requiring close collaboration with propulsion engineers, design engineers, technicians, controls, airframe, and flight test teams.
What you will do in this role:
- Own the propulsion test program from requirements through execution, data review, and test-to-flight handoff.
- Architect, design, analyze, and build test stands and fixtures for engine, fuel, oil, bleed air, and TVC-related testing.
- Define and implement instrumentation plans, DAQ architecture, calibration methods, and test procedures.
- Lead ground test campaigns, including performance mapping, transient response, and edge-of-envelope testing.
- Analyze test data to validate performance, identify anomalies, and drive design or control updates.
- Partner with propulsion REs and controls engineers to ensure test coverage closes risk against CONOPS and mission profiles.
- Drive root cause investigations for test anomalies and implement corrective actions.
- Author test plans, reports, and readiness reviews; represent propulsion test in design and flight readiness reviews.
Required qualifications:
- Bachelor’s degree in Aerospace Engineering or a related engineering discipline.
- 5+ years of experience in propulsion or engine testing in aerospace development environments.
- Hands-on experience with engine test cells, test stand design, instrumentation, and DAQ systems.
- Strong understanding of gas turbine engine performance, transients, and test methodologies.
- Proficiency in Python (or similar) for data reduction, automation, and analysis workflows.
- Experience supporting flight test readiness and test-to-flight transitions.
- U.S. Citizenship or ability to comply with ITAR requirements.
- Ability to obtain a S//SAR level security clearance desired.
Preferred qualifications:
- Experience testing low-bypass turbofan engines or propulsion subsystems on UAVs or tactical aircraft.
- Familiarity with REFPROP, GFSSP, ANSYS, or FEA to support test interpretation and correlation.
- Experience designing structural test fixtures, load paths, thermal management, and safety systems for hot-fire environments.
- Background in controls integration, actuator testing (e.g., TVC), and transient characterization.
- Experience operating in a test-driven, hardware-centric aerospace development environment.
- M.S. in Aerospace Engineering or a related discipline.
Skills Required
- Bachelor's degree in Aerospace Engineering or a related engineering discipline
- 5+ years of experience in propulsion or engine testing in aerospace development environments
- Hands-on experience with engine test cells, test stand design, instrumentation, and DAQ systems
- Strong understanding of gas turbine engine performance, transients, and test methodologies
- Proficiency in Python (or similar) for data reduction, automation, and analysis workflows
- Experience supporting flight test readiness and test-to-flight transitions
- U.S. Citizenship or ability to comply with ITAR requirements
- Ability to obtain a S//SAR level security clearance
- Experience testing low-bypass turbofan engines or propulsion subsystems on UAVs or tactical aircraft
- Familiarity with REFPROP, GFSSP, ANSYS, or FEA to support test interpretation and correlation
- Experience designing structural test fixtures, load paths, thermal management, and safety systems for hot-fire environments
- Background in controls integration, actuator testing (e.g., TVC), and transient characterization
- Experience operating in a test-driven, hardware-centric aerospace development environment
- M.S. in Aerospace Engineering or a related discipline
What the Team is Saying
Shield AI Compensation & Benefits Highlights
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Healthcare Strength — Company materials describe excellent medical, dental, and vision coverage alongside a mental‑health EAP. Site perks such as an onsite gym in DC and a gym discount in San Diego support a health‑focused offering.
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Retirement Support — Careers materials highlight a 401(k) with company match as part of the standard package. A Total Rewards overview emphasizes retirement features within a broader, transparent compensation view.
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Career-Linked Recognition & Rewards — Compensation for in‑demand technical and senior go‑to‑market roles is described as competitive, with visible engineering ranges and top‑end packages. This points to meaningful upside tied to role, level, and scarce skills.
Shield AI Insights
What We Do
Founded in 2015, Shield AI is a venture-backed deep-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include the V-BAT and X-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With offices and facilities across the U.S., Europe, the Middle East, and the Asia-Pacific, Shield AI’s technology actively supports operations worldwide.
Why Work With Us
What makes Shield AI special is our people. We unlock the power of autonomy, and in the face of overwhelming odds and challenges, we find ways to win and make a difference for our customers. We bring together software, AI, and aerospace engineering disciplines to deploy the most intelligent aviation capabilities in the world.
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