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 ResponsibilitiesEngine 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 yearsDomain Expertise: UAV Propulsion Systems, RPA (Remotely Piloted Aircraft), Engine Diagnostics & Calibration