Sr. Propulsion Engineer

AeroVironment • Petaluma, CA

1d

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.

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

• 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.

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: Senior