Senior Engineer – Engine Operations

Senior Engineer – Engine Operations is responsible for the execution and technical validation of UAV propulsion system integration, calibration, and diagnostics. This role oversees bench tests, root cause analysis, scheduled maintenance, and post-flight propulsion assessments, ensuring operational integrity across platforms. The senior engineer mentors junior staff, enforces compliance with airworthiness and QA protocols, and contributes to process improvement initiatives. It plays a pivotal role in defect investigations, system troubleshooting, and cross-team technical handovers during flight readiness and deployment cycles.
Job Responsibilities
Engine System Architecture & Subsystem Integration
Interpret propulsion system blueprints and BOMs to oversee mechanical integration of engine modules, exhaust manifolds, vibration dampers, and thermal insulation systems onto UAVs.
Lead alignment of the engine assembly with airframe CG, thrust line, and cooling airflow zones using CAD overlays and DTI (dimensional tolerance inspection).
Coordinate across mechanical and avionics teams to ensure seamless integration of propulsion with flight control and mission management systems.
Calibration of Propulsion Control Units
Execute advanced calibration of ECU logic, ignition timing, fuel injection curves, and RPM throttling profiles tailored for each mission scenario.
Validate calibration through iterative tuning runs, analyzing feedback loops from in-flight data and adjusting for altitudinal density, payload weight, and loiter duration.
Document baseline, delta, and final calibration sets in configuration control registers and flag deviations for lead review.
Test Bench Operations & Run-Time Monitoring
Oversee pre-bench preparation, including fuel line priming, oil system setup, coolant routing, and sensor calibration before hot engine tests.
Monitor engine performance under full-throttle stress conditions and collect telemetry on thermal response, power output, and vibration thresholds.
Ensure proper functioning of Electronic Speed Controllers (ESCs) and Power Distribution Board (PDB) during high-load test runs, and verify electrical load balancing across propulsion subsystems.
Investigate abnormal operating conditions (e.g., detonation knock, turbo overspeed, injector misfire) and isolate subsystem causes before escalation.
Fault Diagnostics & Troubleshooting
Use telemetry logs, diagnostic codes, and physical inspections to identify root causes of propulsion anomalies (e.g., loss of RPM under load, rising EGT, or oil contamination).
Apply structured problem-solving techniques (5 Whys, FMEA) to eliminate chronic or repetitive engine integration issues.
Prepare fault tree reports for post-mission debriefs and lead multidisciplinary review sessions when major defects are detected.
Scheduled & Predictive Maintenance Leadership
Lead implementation of 25/50/100-hour service protocols for UAV engines, including teardown inspections, part replacements, and system recalibrations.
Perform condition-based diagnostics using tools like digital boroscopes, vibrometers, and oil analysis kits to extend engine life and preempt failures.
Maintain digital logs in ERP/CMMS for all maintenance actions, flagging parts nearing end-of-life or requiring OEM revalidation.
Pre-Flight & Post-Flight Propulsion Validation
Supervise propulsion system sign-offs prior to UAV flight clearance, ensuring all startup diagnostics, ignition logic checks, and thermal system activations pass criteria.
Debrief post-flight engine data (live logs and downloaded telemetry), validating real-time performance against calibrated maps.
Provide feedback to engineering change control teams if configuration changes are needed based on flight behavior.
Technical Oversight & Mentoring
Guide engineers and junior engineers during integration, calibration, and troubleshooting tasks, ensuring adherence to SOPs and engineering judgment.
Review completed installation checklists, calibration records, and maintenance logs for completeness, correctness, and traceability.
Conduct skill-building sessions on interpreting engine data, understanding control loop behavior, and identifying potential failure signatures.
Quality Control, Safety & Compliance
Enforce compliance with STANAG 4671, MIL-STD-810, and internal propulsion system SOPs during integration, calibration, and testing operations.
Participate in quality audits, readiness assessments, and FAI (First Article Inspection) reviews involving propulsion subsystems.
Lead root cause analysis after propulsion-related incidents and implement CAPA (Corrective and Preventive Actions) in collaboration with QA.
Cross-Team Technical Coordination
Act as the propulsion engineering point-of-contact for avionics, airframe, electrical, and GCS teams during integration and test readiness phases.
Support Remote Pilots by interpreting engine behavior in-flight and guiding corrective actions during SATCOM-disconnected events or startup failures.
Provide propulsion performance summaries to the program manager and assist with engine configuration decisions during mission planning.
Process Improvement & Engineering Change Proposals
Identify inefficiencies or repeated error trends in engine operations and propose changes to calibration flow, assembly steps, or diagnostic processes.
Draft and submit Engineering Change Requests (ECRs) for propulsion upgrades, revised component specs, or updated service intervals.
Contribute to internal propulsion R&D efforts and feedback loops for future UAV variants or field performance improvements.
Experience Required: 5–10 years
Domain Expertise: UAV Propulsion Systems, RPA (Remotely Piloted Aircraft), Engine Diagnostics & Calibration

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