Sr. Propulsion Engineer

Worker Type

Job Description
 

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.

Key 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.

Qualifications:

• 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.

Preferred Qualifications:

• 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.

Physical Demands

• Ability to work in an office (Constant)
• Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Frequent)

Clearance Level
 

The salary range for this role is:

AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidate’s work experience, education/training, and key skills.

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.

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.

Principals only need apply.  NO agencies please.

About AV:

AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best.

We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve.

Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next.

If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV.

We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity or other legally protected status.

ITAR