Sr. Propulsion Engineer

AeroVironment • Petaluma, CA

7h

About The Position

We are seeking a Sr. Propulsion Engineer 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.

Requirements

• 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.
• ITAR Requirement: This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (“ITAR”) and/or the Export Administration Regulations (“EAR”). In order to comply with the requirements of the ITAR and/or the EAR, applicants must qualify as a U.S. person under the ITAR and the EAR, or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A “U.S. person” according to the ITAR definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee or asylee. See 22 CFR § 120.15.
• Some positions will require current U.S. Citizenship due to contract requirements.

Nice To Haves

• 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.

Responsibilities

• 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.
• 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).
• 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.
• 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.
• 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.

Benefits

• AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown.
• For more information about our company benefit offerings please visit: http://www.avinc.com/myavbenefits .
• We also encourage you to review our company website at http://www.avinc.com to learn more about us.

What This Job Offers

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