Senior Engineer

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