Senior Staff Engineer – Environmental Control Systems (RX)

About the role

Shield AI is seeking a Senior Staff Engineer to lead the Environmental Control System (ECS) architecture, analysis, design, and integration for a dedicated special‑access aircraft program. The role combines deep technical expertise with rapid‑iteration development to deliver flight‑ready hardware.

Key responsibilities

• Define ECS architecture and conduct trade studies (vapor cycle, air cycle, passive/ram‑air) against thermal, electrical, mass and volume constraints.
• Design and analyze air inlets, scoops, ducting networks and ram‑air cooling circuits across the flight envelope.
• Perform first‑principles thermodynamic and heat‑transfer calculations supported by 1‑D fluid‑thermal network models.
• Write technical specifications and statements of work for heat exchangers, fans, valves, compressors and sensors; evaluate vendors and manage supplier execution.
• Develop qualification and verification test plans, design test rigs, set up instrumentation and execute test campaigns.
• Process flight‑test data, troubleshoot anomalies, and implement rapid design changes.

Required profile

• U.S. citizen with an active Secret clearance or higher.
• 8–15 years of aerospace ECS and vehicle thermal/fluid system development experience.
• B.S. or M.S. in Mechanical Engineering, Aerospace Engineering or a related discipline.
• Deep mastery of thermodynamics, fluid dynamics and heat transfer applied to aircraft or defense systems.
• Proven ability to source COTS/custom aerospace components and drive suppliers to schedule.
• Self‑directed work style with the capacity to prioritize tasks and deliver hardware under tight timelines.

Required skills

• 1‑D system modeling tools such as Amesim, Flowmaster, or Python/MATLAB fluid networks.
• 3D CAD modeling and PLM workflows – Siemens NX preferred, CATIA or Creo acceptable.