Overview
This role covers the selection, integration, calibration and testing of internal-combustion propulsion systems for unmanned aircraft. The engineer works with the mechanical, aerostructures and electrical teams to adapt engine hardware, installations and controls to aircraft performance and mission requirements.
Core responsibilities
- Select and match engines and propellers to mission requirements, including performance at altitude and fuel consumption.
- Design fuel, air-intake, cooling and exhaust systems, and define installation requirements (mount loads, vibration isolation and clearances) for the mechanical and structures engineers.
- Set up and calibrate engine control units (ECUs) to control electronic fuel injection (EFI) and ignition, and tune engine operation across the required operating range.
- Plan and execute engine test programmes. Specify the test bench and instrumentation with the mechanical and electrical engineers; conduct run-in, performance and reliability tests; map power, torque and thrust against speed; and assess fuel pressure, fuel mass flow, exhaust oxygen (air-fuel ratio), cylinder-head and exhaust-gas temperatures, and fuel efficiency.
- Conduct engine ground tests on the aircraft, troubleshoot and maintain engines, and own fuel-handling and engine-run safety procedures.
- Design engine components and installations in CAD; customise or adapt available engine hardware, using reverse engineering where appropriate, and develop and calibrate engine controls to suit the aircraft.
- Support flight testing and analyse flight logs to assess engine performance and thermal behaviour; document designs, tests and decisions.
Qualifications
Essential
- B.E./B.Tech in Mechanical, Automobile or Aerospace Engineering.
- 0–2 years of experience.
- Strong fundamentals in IC engines, thermodynamics and machine design.
- Strong 3D CAD skills (preferably SolidWorks), including part modelling, assemblies and drawings.
- Hands-on engine experience, including assembly, servicing, starting and safe operation.
Preferred
- Powertrain experience in an SAE BAJA, Formula SAE or similar team.
- Experience tuning EFI-equipped IC engines through ECU calibration using tuning software.
- Experience with small engines or RC aero engines.
- Automotive or two-wheeler powertrain experience.
- Knowledge of data acquisition and sensors.
- Experience with reverse engineering and dimensional inspection of engine components.
- Programming in Python or MATLAB for test-data analysis.