Electrical Propulsion Engineer (Fixed-Wing & VTOL UAVs)

Electrical Propulsion Engineer (Fixed-Wing & VTOL UAVs)

Role Overview

We are seeking an Electrical Propulsion Engineer specializing in small, non-quadcopter Unmanned Aerial Vehicles (UAVs) to lead the design, selection, and optimization of our aircraft powertrains. In this role, you will focus on maximizing aerodynamic range, mission flight time, and system reliability for complex airframes, including high-endurance fixed-wing aircraft, hybrid VTOLs, tilt-rotors, and novel aerodynamic platforms .

You will bridge the gap between electrical engineering and aerodynamics. You will select, modify, and optimize components to achieve the highest possible power density while strictly managing thermal profiles and battery degradation. You will collaborate with aerospace and firmware engineers to build cohesive, lightweight powertrain systems.

Key Responsibilities

Powertrain Component Selection & Design

• Optimize System Trade-offs: Architect the entire electrical propulsion system, selecting and mating brushless DC (BLDC) or PMSM motors, Electronic Speed Controllers (ESCs), and propellers optimized for forward cruise efficiency rather than just static hover.
• Custom Battery Architecture: Design, model, and integrate high-energy-density battery packs ( Lithium-ion, Lithium-polymer, or solid-state ) with advanced Battery Management Systems (BMS).
• Thermal Management: Design lightweight passive or active cooling paths to handle continuous high-current draws during demanding cruise and climb flight profiles.

Simulation, Integration & Power Budgeting

• Perform Trade Studies: Analyze and simulate the powertrain's performance using tools like MATLAB, Simulink, or custom scripts to build highly accurate power budgets and range/endurance estimators .
• Optimize Efficiency: Tailor motor winding, ESC commutation settings), and propeller pairing to hit peak efficiency sweet spots during the aircraft's cruising speeds.
• EMI/EMC Mitigation: Route and shield high-power electrical systems to minimize electromagnetic interference affecting sensitive onboard RF communications, GPS, and avionics.

Testing & Validation

• Dynamometer Testing: Conduct automated static and dynamic thrust-stand testing to characterize motor-propeller efficiencies, transient throttle responses, and structural vibrations.
• Flight Data Analysis: Analyze telemetry logs from real-world test flights to validate simulated energy consumption models and continuously iterate on the powertrain design.

Required Skills & Qualifications

• Education: Bachelor’s or Master’s degree in Electrical Engineering, Aerospace Engineering, Mechatronics, or a related field.
• Component Expertise: Deep technical understanding of BLDC/PMSM motors, ESC architectures, FOC firmware, and lithium-based battery safety metrics.
• Aerodynamic Awareness: Broad comprehension of propeller aerodynamics, advance ratios, and how thrust requirements differ between static hover and high-speed forward flight.
• Simulation Tools: Experience utilizing powertrain simulation tools (e.g., MATLAB/Simulink, eCalc, or internal Python analysis scripts).
• Lab Equipment Fluency: Hands-on proficiency using oscilloscopes, power analyzers, electronic loads, and thrust stands.

Preferred Qualifications

• Direct experience engineering propulsion for fixed-wing UAVs or complex hybrid transition VTOL aircraft.
• Experience writing or modifying low-level ESC firmware
• Background in design for manufacturing (DFM) and aerospace-grade weight reduction techniques.

About Knightwerx

Knightwerx develops American-made, AI-powered unmanned aerial systems and remote sensing technologies for commercial and government customers. Our platforms support autonomous operations, human-machine teaming, and mission-critical applications where reliability, performance, and speed matter.