Sr. Flight Test Engineer

Senior Flight Test Engineer

We are seeking a self-motivated Senior Flight Test Engineer to join our team. The engineer will assist in the multi-functional product development of new designs while collaborating with other engineering disciplines and project personnel. You will play a crucial role in the planning, execution, and analysis of flight tests for unmanned aerial vehicles (UAVs). You will work with cross-functional teams to develop test plans, conduct flight tests, and ensure that UAV systems meet performance, safety, and reliability standards. This position requires a strong background in aerospace engineering, a deep understanding of UAV systems, and experience in flight testing. This role involves working on multiple platforms and vehicles, supporting both ground and flight-testing operations.

Responsibilities and Duties:

• Provide testing and flight-testing support for company projects.

• Develop and maintain high-quality testing documentation to include detailed test plans that describe objectives, methodologies, safety protocols, and resource requirements

• Represent testing interests when collaborating with project teams.

• Work with design engineers, systems engineers, and software developers to define specific test requirements and procedures and develop engineering test strategies for new and existing products.

• Collaborate with assembly and engineering personnel to test prototype units and ensure proper execution and documentation.

• Conduct pre-flight inspections and system checks to ensure the readiness of UAVs for testing.

• Lead or participate in the execution of flight tests.

• Monitor and analyze flight data in real-time to ensure the achievement of test objectives.

• Conduct risk assessments and develop mitigation strategies to ensure safe operations.

• Lead post-test debriefs to identify lessons learned and incorporate them into future testing.

• Work with field service personnel and engineers to create test procedures addressing specific product issues observed in the field.

• Act as an engineering interface to resolve production test issues.

• Train personnel in proper testing techniques.

• Look for improvements throughout the testing process to reduce costs or improve test coverage.

• Support the creation of system requirements, trade studies, sub-component, and flight test plans.

• Coordinate with suppliers, internal and external integrated product teams.

• Provide manufacturing, component test, and ground/flight test support.

• Investigate and determine root cause of component failures and recommend corrective actions.

• Develop engineering drawings, schematics, and design specifications.

• Ensure circuit protection, isolation, redundancy, and fault tolerance for flight systems.

• Present results through technical drawings, written reports, and oral presentations to customers and senior project management.

• Mentor and guide junior flight test engineers

Required Qualifications and Skills:

• Bachelor’s degree in engineering or equivalent.

• 5-8 years of experience in aerospace engineering, with at least 3-5 years in UAV flight testing or a closely related field. Hands-on experience in planning and conducting flight tests for unmanned systems.

• Experience with power distribution systems theory, design, test, or analysis.

• Experience with electric motor and controller/inverter theory, design, test, or analysis.

• Able to work with high voltage (>500V).

• Strong analytical and problem-solving skills.

• Proficiency in flight test software and simulation tools.

• Excellent communication and teamwork abilities.

• Ability to work in a fast-paced, dynamic environment.

• Understanding of structures, mechanisms, system layout, materials, and processes.

• Experience with data collection and reduction software (LabView, MatLab).

• Proficiency with the Microsoft Office Suite (Word, Excel, PowerPoint).

• Experience with SolidWorks and SolidWorks PDM (or similar).

• Structural or thermal analysis of structures and systems.

• Part 107 pilot qualified, or ability to obtain

• US Citizenship Required.

Desired Qualifications and Skills:

• Master’s degree in Aero or Mechanical Engineering or equivalent and/or 5+ years of experience.

• Familiarity with electronics testing.

• Experience with digital communication protocols such as SPI, Ethernet, and CAN bus.

• Experience in UAS design.

• Familiarity with Military standards for aircraft design and electromagnetic compatibility.

• Experience with metallic and composite design and analysis.

• Experience with design for manufacturing and advanced manufacturing processes.

• Hands-on experience working with machine shops, integrating prototype designs, and conducting validation tests.

• Strong organizational skills and attention to detail.

• Experience with supplier management and procurement (e.g., SOWs, RFPs, vendor management).

• Familiarity with Risk Management.

• Ability to work on DoD projects.

Comprehensive Benefits & Perks:

• Health & Wellness: Choose from three health, dental, and vision plans - including a 100% employer-paid option covering both employees and their families.

• Paid Time Off: Enjoy 120 hours of PTO, 80 hours accrued plus an additional 40 hours of holiday break pay in addition to Christmas Eve, Christmas Day, and New Year’s Day off.

• Life Insurance: $25,000 employer-paid life insurance policy, with the option to purchase additional coverage for employees and their families.

• Supplemental Coverage: Access optional benefits such as Critical Illness, Hospital Indemnity, Accident Insurance, and Critical Illness with Skin Cancer coverage.

• Health Savings Account (HSA): Take advantage of a tax-advantaged HSA to manage medical expenses.

• Retirement Savings: 401(k) with a company match to support your financial future.

• Paid Holidays: Enjoy 9 paid holidays throughout the year.

• Work Environment: A casual dress code, complimentary snacks, and a welcoming company culture.

• Ideal Location: Work in an area that offers an outstanding quality of life - a perfect place to live, work, and play!

Company Overview:

Empirical Systems Aerospace, Inc (ESAero) is a leader in aerospace engineering, product development, and manufacturing, dedicated to delivering high-quality, innovative, and cost-effective solutions to the industry. We specialize in cutting-edge system design, rapid product development, precision manufacturing, comprehensive testing, and technology demonstrations to support the evolving needs of the aerospace community. Committed to excellence, on-time delivery, and continuous growth, we invest in infrastructure to expand our manufacturing and aftermarket capabilities while maintaining the highest standards of engineering services.

At ESAero, we don’t just build products, we engineer solutions that propel

the aerospace industry forward.

**This position is fully on-site at ESAero in San Luis Obispo, CA**

__________________________________________________________________________

ESAero is an equal opportunity employer.
E-Verify participation required for employment.
All ESAero positions require US citizenship or US resident status.
Must be able to pass background check and drug screening.
Pay Range: $110-$140k Salary Exempt