Electric Propulsion Engineer

The Structures Company•Irvine, CA

2d•Onsite

About The Position

Leads selection, sizing, and integration of electric propulsion components including ducted fans, open propellers, motors, motor controllers, and batteries. Performs system-level trade studies to balance thrust, efficiency, thermal performance, weight, and mission endurance. Conducts tuning, calibration, and performance optimization of motors and motor controllers across varying load conditions and flight profiles. Develops propulsion test plans and supports bench testing, ground testing, and flight testing activities. Analyzes test data and generates recommendations to improve system reliability, safety margins, and energy efficiency. Collaborates with aerodynamics, airframe, avionics, and systems engineering teams to ensure seamless integration of propulsion systems. Creates technical documentation including specifications, integration guides, and validation reports. Contributes to failure mode analysis, thermal modeling, and risk mitigation related to electric propulsion hardware. Maintains awareness of emerging technologies, supplier capabilities, and industry best practices in electric propulsion for small unmanned aircraft. Uses propulsion modeling tools and instrumentation for data capture and performance analysis.

Requirements

Ability to obtain and maintain a Secret Security Clearance
Must be a U.S. Person (as defined by ITAR)
Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Electrical Engineering, or a related field
5-7 years of direct experience in electric propulsion within the aerospace or UAV industry
Hands-on experience selecting and tuning ducted fans, propellers, motors, ESCs, and batteries for Group 1-2 aircraft
Strong familiarity with propulsion performance metrics (thrust, RPM, torque, efficiency, voltage sag, thermal behavior)
Experience with propulsion modeling tools and instrumentation for data capture
Proven ability to diagnose and resolve propulsion-related integration and performance issues

Nice To Haves

Proficiency in MATLAB for data analysis and modeling
Proficiency with 3D CAD systems, with SolidWorks preferred
Experience developing test plans and supporting bench, ground, and flight testing activities

Responsibilities

Selection, sizing, and integration of electric propulsion components (ducted fans, open propellers, motors, motor controllers, batteries)
Performing system-level trade studies to balance thrust, efficiency, thermal performance, weight, and mission endurance
Tuning, calibration, and performance optimization of motors and motor controllers
Developing propulsion test plans and supporting bench, ground, and flight testing
Analyzing test data and generating recommendations for system improvement
Collaborating with aerodynamics, airframe, avionics, and systems engineering teams
Creating technical documentation (specifications, integration guides, validation reports)
Contributing to failure mode analysis, thermal modeling, and risk mitigation
Maintaining awareness of emerging technologies and industry best practices
Using propulsion modeling tools and instrumentation for data capture and performance analysis