Staff Mechanical Engineer – Propulsion
$145,000–$165,000 year
On-siteSan Diego, California, United States
Job Summary
Own development and integration of small piston engines and micro turbojet propulsion systems, including engine selection, inlet/exhaust configuration, and thrust characterization. Execute engine test plans on test stands and in-flight for power mapping, BSFC analysis, and endurance runs. Lead ECU calibration and tuning for EFI-equipped powerplants, while designing fuel systems across the full flight envelope. Investigate propulsion anomalies to develop structured test plans and drive corrective actions. Specify and qualify propellers in coordination with aerodynamics, and maintain engineering documentation including test reports and configuration baselines. Partner with thermal and electrical engineering teams, interface with OEMs for procurement, and travel up to 20% domestically for testing. Based in San Diego, CA with a standard office and manufacturing environment.
Required Qualifications
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field (Master's degree preferred)
- 7+ years of experience in propulsion engineering, preferably with small piston engines, heavy-fuel engines, or small gas turbines
- Deep working knowledge of internal combustion fundamentals: thermodynamic cycles, AFR, combustion, knock, ignition systems, and exhaust
- Hands-on experience designing and operating engine test stands, including dyno instrumentation, fuel flow measurement, EGT/CHT instrumentation, and data acquisition
- Experience with EFI systems and ECU calibration (EFI Technology, MoTeC, Currawong, or equivalent)
- Experience with fuel system design across the full flight envelope—including altitude, attitude, and thermal effects on fuel delivery and pressure
- Demonstrated history of running structured failure investigations and translating findings into multi-phase test campaigns
- Proficiency in Python or MATLAB for engine data reduction, log analysis, and performance modeling
- Familiarity with propeller selection and matching for fixed-wing platforms
- Excellent problem-solving skills and attention to detail
- Strong communication and teamwork skills
- Ability to work in a fast-paced and dynamic startup environment
- U.S. Citizenship and ability to obtain and maintain a U.S. Government security clearance
Desired Qualifications
- Experience with sUAS or Group 1–3 unmanned aircraft propulsion
- Experience with heavy-fuel (JP-5/JP-8) engine integration and qualification
- Experience reverse-engineering proprietary ECU data formats or building custom log analysis pipelines
- Background in flight test, including FAA Part 107 or Part 61 operations
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