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Shield AI

Posted 2 months ago

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Senior Propulsion Test Engineer (R4640)

DallasOn-siteFull-time

AI Summary

Senior Propulsion Test Engineer who leads propulsion test campaigns, designs test stands and instrumentation, analyzes data, and coordinates test-to-flight handoffs for UAV propulsion systems.

About this role

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. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description:

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.

    • 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

    AnsysCalibration MethodsChallenge And Edge-of-envelope TestingControls IntegrationDAQ SystemsData ReductionEngine Test CellsFEAGas Turbine Engine PerformanceGFSSPInstrumentation PlanningPropulsion TestingPythonRefPropSafety SystemsStructural Test FixturesTest ProceduresTest Stand DesignTest-to-flight TransitionThermal ManagementTransientsTVC Actuation

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