Senior Flight Test Engineer

Empirical Systems Aerospace, Inc. • San Luis Obispo, CA

22h • $100,000 - $154,000 • Onsite

About The Position

Empirical Systems Aerospace, Inc. (ESAero) is seeking a self-motivated Senior Flight Test Engineer to support multidisciplinary product development and the planning, execution, and analysis of UAV flight tests. The role works across multiple platforms and vehicles, supporting ground and flight-testing operations and collaborating with engineering disciplines, project personnel, suppliers, and integrated product teams to ensure systems meet performance, safety, and reliability standards.

The engineer develops test strategies, requirements, procedures, and documentation; supports prototype, manufacturing, component, ground, and flight testing; and analyzes test results and failures. The position also involves developing engineering drawings, schematics, and design specifications; presenting results to customers and senior project management; training personnel; and mentoring junior flight test engineers.

This position is fully on-site in San Luis Obispo, California. U.S. citizenship or U.S. resident status is required. Candidates must be able to pass a background check and drug screening. The role is salary exempt, with a pay range of $100,000–$154,000.

Requirements

• Bachelor’s degree in engineering or equivalent.
• 5–8 years of aerospace engineering experience, including at least 3–5 years in UAV flight testing or a closely related field.
• Hands-on experience planning and conducting flight tests for unmanned systems.
• Experience with power distribution systems theory, design, testing, or analysis.
• Experience with electric motor and controller/inverter theory, design, testing, or analysis.
• Ability to work with high voltage (>500V).
• Strong analytical and problem-solving skills.
• Proficiency in flight-test software and simulation tools.
• Excellent communication and teamwork abilities.
• Ability to work in a fast-paced, dynamic environment.
• Understanding of structures, mechanisms, system layout, materials, and processes.
• Experience with data collection and reduction software such as LabView and MatLab.
• Proficiency with Microsoft Office Suite (Word, Excel, and PowerPoint).
• Experience with SolidWorks and SolidWorks PDM or similar tools.
• Experience with structural or thermal analysis of structures and systems.
• Part 107 pilot qualification, or ability to obtain it.
• U.S. citizenship required.

Nice To Haves

• Master’s degree in aerospace or mechanical engineering or equivalent and/or 5+ years of experience.
• Familiarity with electronics testing.
• Experience with digital communication protocols such as SPI, Ethernet, and CAN bus.
• Experience in UAS design.
• Familiarity with military standards for aircraft design and electromagnetic compatibility.
• Experience with metallic and composite design and analysis.
• Experience with design for manufacturing and advanced manufacturing processes.
• Hands-on experience working with machine shops, integrating prototype designs, and conducting validation tests.
• Strong organizational skills and attention to detail.
• Experience with supplier management and procurement, including SOWs, RFPs, and vendor management.
• Familiarity with risk management.
• Ability to work on DoD projects.

Responsibilities

• Provide testing and flight-testing support for company projects.
• Develop and maintain test documentation, including detailed test plans describing objectives, methodologies, safety protocols, and resource requirements.
• Represent testing interests when collaborating with project teams.
• Work with design engineers, systems engineers, and software developers to define test requirements and procedures and develop engineering test strategies for new and existing products.
• Collaborate with assembly and engineering personnel to test prototype units and ensure proper execution and documentation.
• Conduct pre-flight inspections and system checks to ensure UAV readiness for testing.
• Lead or participate in flight-test execution.
• Monitor and analyze flight data in real time to assess whether test objectives are being achieved.
• Conduct risk assessments and develop mitigation strategies for safe operations.
• Lead post-test debriefs, identify lessons learned, and apply them to future testing.
• Work with field service personnel and engineers to create test procedures addressing product issues observed in the field.
• Act as an engineering interface to resolve production test issues.
• Train personnel in proper testing techniques.
• Identify improvements to testing processes to reduce costs or improve test coverage.
• Support the creation of system requirements, trade studies, and sub-component, ground, and flight-test plans.
• Coordinate with suppliers and internal and external integrated product teams.
• Provide manufacturing, component-test, and ground- and flight-test support.
• Investigate component failures, determine root causes, and recommend corrective actions.
• Develop engineering drawings, schematics, and design specifications.
• Ensure circuit protection, isolation, redundancy, and fault tolerance for flight systems.
• Present results through technical drawings, written reports, and oral presentations to customers and senior project management.
• Mentor and guide junior flight test engineers.

Benefits

• Three health, dental, and vision plans, including a 100% employer-paid option covering employees and their families.
• 120 hours of PTO: 80 hours accrued plus 40 hours of holiday break pay.
• Christmas Eve, Christmas Day, and New Year’s Day off.
• $25,000 employer-paid life insurance policy, with the option to purchase additional coverage for employees and their families.
• Optional supplemental coverage, including Critical Illness, Hospital Indemnity, Accident Insurance, and Critical Illness with Skin Cancer coverage.
• Health Savings Account (HSA).
• 401(k) with company match.
• Nine paid holidays throughout the year.
• Casual dress code and complimentary snacks.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior