Senior Propulsion Design Engineer (R4642)

We are seeking a Senior Propulsion Design Engineer to support the development and delivery of propulsion hardware for the X-BAT platform, a next-generation UAV powered by a low-bypass turbofan engine. This role spans the full lifecycle of propulsion system components - from early layout and design through production release, test support, and flight operations.

You will be a key contributor to turning propulsion architecture into manufacturable, testable, and flight-ready hardware across the engine, fuel, oil, and bleed air systems. This role is hands-on, detail-oriented, and highly cross-functional - requiring close collaboration with propulsion REs, technicians, machinists, production, controls, airframe, and flight test teams.

What you will do in this role:

• Own the design and release of propulsion hardware supporting the engine, fuel, oil, and bleed air systems.
• Develop and maintain CAD models, drawings, and assemblies using Siemens NX with proper GD&T.
• Translate propulsion architecture and requirements into hardware that is manufacturable, testable, and robust in flight.
• Work directly with the machine shop, production, and technicians to support builds, resolve non-conformances, and drive iterative improvements.
• Support test campaigns by providing hardware design support, instrumentation accommodation, and rapid iteration based on test findings.
• Apply engineering judgment and analysis (e.g., hand calcs, ANSYS, FEA, GFSSP, 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 efforts, and root cause investigations related to propulsion hardware.

Required qualifications:

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, or a related engineering discipline.
• 5+ years of experience in aerospace hardware design, preferably supporting propulsion systems.
• Proficiency in CAD modeling and drawing creation (NX preferred) with sound application of GD&T.
• Experience working directly with production, technicians, and machine shops to resolve real-world build issues.
• Understanding of design for manufacturing, including machining limitations, tolerance stack-ups, and assembly workflows.
• Some hands-on experience developing assembly guidance and supporting hardware builds and test integration.
• U.S. Citizenship or ability to comply with ITAR requirements.
• Ability to obtain a S//SAR level security clearance desired.

Preferred qualifications:

• Experience with jet propulsion systems on UAVs or tactical aircraft.
• Familiarity with GFSSP, REFPROP, ANSYS, or FEA to support design trade studies and validation.
• Ability to write Python scripts for design automation, analysis, or data processing.
• Experience with interface control, fastener selection for high-vibration environments, and high-temperature materials.
• Experience designing hardware in test-driven development environments with rapid iteration cycles.
• M.S. in Aerospace Engineering or a related discipline.