Lead end-to-end propulsion test campaigns for a low-bypass turbofan Group 5 UAV: design test stands and instrumentation, execute ground tests, analyze data, drive anomaly investigations, and coordinate test-to-flight handoffs with cross-functional teams.
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, V-BAT and X-BAT aircraft, and Aechelon simulation and synthetic reality technologies. 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.
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.
- 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.
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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.
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Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.
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