Staff Propulsion Design Engineer

We are seeking a Staff Propulsion Design Engineer to lead the development and delivery of hardware supporting the propulsion system of a low-bypass turbofan-powered UAV. This includes components for the engine, fuel, oil, and bleed air systems—from early layout and design through production release, test support, and flight operations.

You will join at the earliest stages of platform development and serve as a driving force in turning propulsion architecture into manufacturable, testable, and flight-ready hardware. This role is highly cross-functional, sitting at the intersection of design execution, propulsion integration, and vehicle performance.

We’re looking for an experienced engineer with deep technical intuition, fluency in CAD and design-for-manufacturing, and a passion for building robust systems that perform in high-consequence environments.

What you will do in this role:

• Own the design of propulsion components and subsystems from concept through production release
• Develop and maintain high-quality CAD models, detailed drawings, and assemblies using Siemens NX with fully applied GD&T
• Write and enforce propulsion design standards and contribute to company-wide design best practices
• Collaborate closely with the machine shop, production team, and technicians to support builds, resolve non-conformances, and drive iterative improvements
• Develop initial work instructions, assembly guidance, and design documentation for repeatability and scalability
• Ensure designs are practical, manufacturable, and cost-effective, with strong understanding of machining, tolerances, materials, and assembly workflows
• Apply engineering analysis and judgment (e.g., hand calcs, GFSSP, ANSYS, FEA, REFPROP) to support sizing, load cases, and design validation
• Support configuration management, BOM control, and change processes using Teamcenter or equivalent PLM
• Participate in design reviews, interface control working groups, and root cause investigations

Required qualifications:

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline
• 7+ years of experience in mechanical design for aerospace, with direct propulsion hardware experience preferred
• Expert-level proficiency in CAD modeling and drawing creation (NX preferred) and application of GD&T
• Proven ability to work cross-functionally with production, machine shop personnel, and technicians to solve real-time hardware issues
• Familiarity with design for manufacturing, including machining processes, surface modeling, stack-up analysis, and fabrication limitations
• Hands-on experience developing assembly work instructions, troubleshooting build issues, and implementing hardware-driven design changes
• Experience with configuration management, PLM systems (Teamcenter), and BOM structure
• U.S. Citizenship or ability to comply with ITAR requirements

Preferred qualifications:

• Experience with GFSSP, REFPROP, ANSYS, FEA, or other mechanical and thermal analysis tools
• Ability to write Python scripts for design automation, data analysis, or simulation support
• Proficient in interface control and tolerance stack-up analysis for complex assemblies
• Knowledge of fastening methods and joint design for high-vibration, aerospace environments
• Familiarity with high-temperature materials and design practices for thermally stressed components
• Prior experience designing hardware for internal combustion, turbine, or rocket propulsion systems, particularly in development or test environments
• M.S. or Ph.D. in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline