Propulsion Engineer, Sr.

Worker Type

Regular

Job Description

 

Summary

We are seeking a Propulsion Engineer, Sr. to oversee the integration, validation, and lifecycle management of propulsion systems for our UAV platforms. This role requires a multi-disciplinary leader who can bridge mechanical, aerospace, and systems engineering to ensure engines (including heavy fuel and gas-powered systems) meet performance, weight, endurance, and environment requirements for Group 3 UAVs. The ideal candidate will have a strong background in propulsion system integration, vendor collaboration, and UAV development.

Position Responsibilities:

• Propulsion System Leadership

  • Act as the technical authority for propulsion systems

  • Define system requirements, responsible for engine integration and verification methods

  • Collaborate with vendors to troubleshoot performance issues and drive design improvements.

• Cross-Functional Integration

  • Work with aerodynamics, structural, and avionics teams to optimize engine placement, cooling, and vibration mitigation.

  • Ensure propulsion systems align with UAV mission profiles (e.g., endurance, payload capacity, altitude, temperature, and other environmental factors).

• Testing & Validation

  • Lead ground and flight testing campaigns to validate engine performance under operational conditions.

  • Analyze data to refine system parameters and ensure compliance with military standards.

• Vendor & Customer Management

  • Serve as the primary technical liaison between internal teams and propulsion system vendors.

  • Review vendor designs, conduct risk assessments, and ensure deliverables meet project timelines.

  • Support customer engagements to resolve requirements ambiguity and confusion.

• Lifecycle Support:

  • Develop maintenance protocols and failure-mode analyses for propulsion systems.

  • Support field operations teams in diagnosing and resolving engine-related issues.

  • Develop and maintain strategic alignment of Maintenance, Repair and Overhaul (MRO) operations.

Basic Qualifications (Required Skills & Experience):

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or related field (Master’s preferred).

• 8+ years of systems engineering development experience

• 5+ years in propulsion system design, integration, and test, preferably with gas or heavy fuel engines.

• Knowledge of power and propulsion system and subsystem components such as fuel systems, emissions control, propulsion-airframe integration, and ground equipment.

• Proven experience managing vendor partnerships and cross-functional engineering teams.

• Strong project management abilities (Agile, SCRUM, or similar frameworks).

• Ability to thrive in a fast-paced, dynamic environment, managing multiple priorities and deadlines.

• Excellent communication skills for technical and non-technical stakeholders.

Other Qualifications & Desired Competencies:

• Background in UAV development, particularly Group 2/3 UAVs or similar mid-sized platforms.

• Experience with heavy fuel engines and maritime operations.

• Knowledge of DO-160, MIL-STD-461, or other aerospace environmental testing standards.

• Prior technical lead roles in UAV or defense/aerospace projects.

Physical Demands:

• Ability to work in an office environment (Constant)

• Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Frequent)

Special Requirements:

• U.S. Citizen, U.S. Permanent Resident (Green Card holder) or asylee/refugee status as defined by 8 U.S.C. 1324b(a)(3) required.

• Occasionally may be required to travel within the Continental U.S.

The salary range for this role is:

$136,807 - $194,040

AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidate’s work experience, education/training, and key skills.

ITAR Requirement:

This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (“ITAR”) and/or the Exp