Senior Flight Test Engineer We are seeking a self-motivated Senior Flight Test Engineer to join our team. The engineer will assist in the multi-functional product development of new designs while collaborating with other engineering disciplines and project personnel. You will play a crucial role in the planning, execution, and analysis of flight tests for unmanned aerial vehicles (UAVs). You will work with cross-functional teams to develop test plans, conduct flight tests, and ensure that UAV systems meet performance, safety, and reliability standards. This position requires a strong background in aerospace engineering, a deep understanding of UAV systems, and experience in flight testing. This role involves working on multiple platforms and vehicles, supporting both ground and flight-testing operations.
Responsibilities and Duties: - Provide testing and flight-testing support for company projects.
- Develop and maintain high-quality testing documentation to include detailed test plans that describe 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 specific 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 the readiness of UAVs for testing.
- Lead or participate in the execution of flight tests.
- Monitor and analyze flight data in real-time to ensure the achievement of test objectives.
- Conduct risk assessments and develop mitigation strategies to ensure safe operations.
- Lead post-test debriefs to identify lessons learned and incorporate them into future testing.
- Work with field service personnel and engineers to create test procedures addressing specific product issues observed in the field.
- Act as an engineering interface to resolve production test issues.
- Train personnel in proper testing techniques.
- Look for improvements throughout the testing process to reduce costs or improve test coverage.
- Support the creation of system requirements, trade studies, sub-component, and flight test plans.
- Coordinate with suppliers, internal and external integrated product teams.
- Provide manufacturing, component test, and ground/flight test support.
- Investigate and determine root cause of component failures 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
Required Qualifications and Skills: - Bachelor's degree in engineering or equivalent.
- 5-8 years of experience in aerospace engineering, with at least 3-5 years in UAV flight testing or a closely related field. Hands-on experience in planning and conducting flight tests for unmanned systems.
- Experience with power distribution systems theory, design, test, or analysis.
- Experience with electric motor and controller/inverter theory, design, test, or analysis.
- Able 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 (LabView, MatLab).
- Proficiency with the Microsoft Office Suite (Word, Excel, PowerPoint).
- Experience with SolidWorks and SolidWorks PDM (or similar).
- Structural or thermal analysis of structures and systems.
- Part 107 pilot qualified, or ability to obtain
Desired Qualifications and Skills: - Master's degree in Aero 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 (e.g., SOWs, RFPs, vendor management).
- Familiarity with Risk Management.
- Ability to work on DoD projects.
Comprehensive Benefits & Perks: - Health & Wellness: Choose from three health, dental, and vision plans - including a 100% employer-paid option covering both employees and their families.
- Paid Time Off: Enjoy 120 hours of PTO, 80 hours accrued plus an additional 40 hours of holiday break pay in addition to Christmas Eve, Christmas Day, and New Year's Day off.
- Life Insurance: $25,000 employer-paid life insurance policy, with the option to purchase additional coverage for employees and their families.
- Supplemental Coverage: Access optional benefits such as Critical Illness, Hospital Indemnity, Accident Insurance, and Critical Illness with Skin Cancer coverage.
- Health Savings Account (HSA): Take advantage of a tax-advantaged HSA to manage medical expenses.
- Retirement Savings: 401(k) with a company match to support your financial future.
- Paid Holidays: Enjoy 9 paid holidays throughout the year.
- Work Environment: A casual dress code, complimentary snacks, and a welcoming company culture.
- Ideal Location: Work in an area that offers an outstanding quality of life - a perfect place to live, work, and play!
**This position is fully on-site at ESAero in San Luis Obispo, CA**
Pay Range: $110-$140k Salary Exempt
