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Salary: USD 180,000 - 215,000 / annual
Firestorm is a Series A defense technology company building expeditionary autonomous systems and deployable manufacturing infrastructure. This Staff Mechanical Engineer, Propulsion role owns the complete propulsion architecture for small unmanned aircraft systems (sUAS), from engine selection and integration through qualification and field support.
You will be the technical authority for all propulsion systems across Firestorm's fuel-based aircraft platforms. Responsibilities include:
• Engine Development & Integration: Own selection, inlet/exhaust configuration, fuel and ignition architecture, and thrust/power characterization for both small piston engines and micro turbojet systems. Lead ground and flight test campaigns tailored to each propulsion type.
• Engine Testing & Calibration: Develop and execute comprehensive test plans including power/torque mapping, BSFC characterization, endurance runs, vibration surveys, and altitude/temperature performance testing. Lead calibration of EFI-equipped powerplants, managing AFR targets, EGT management, ignition timing, and injector strategy. Identify and mitigate cylinder-to-cylinder variability.
• Fuel System Design & Analysis: Design and analyze fuel systems (tanks, lines, pumps, filters, regulators, pressure management) across the full flight envelope, accounting for negative-G, altitude, and thermal effects.
• Failure Investigation & Root Cause Analysis: Investigate propulsion anomalies (RPM collapse, lean events, misfires, mechanical failures). Develop structured multi-phase test plans and drive corrective action using RCA, FMEA, FMECA, or FTA methodologies.
• Propeller Specification & Qualification: Specify and qualify propellers in coordination with aerodynamics, balancing thrust, efficiency, ground clearance, acoustic signature, and vibration.
• Documentation & Stakeholder Management: Develop and maintain propulsion engineering documentation including interface control documents, test plans/reports, propulsion budgets, and configuration baselines. Interface with engine OEMs, fuel system vendors, and propeller manufacturers as the technical lead for procurement and qualification.
• Cross-Functional Collaboration: Partner with thermal engineering on engine cooling and heat rejection; partner with electrical engineering on ECU integration, sensor selection, harnessing, and telemetry.
• Field Support: Travel to test sites and customer locations (up to 20% domestically) to support propulsion test events and field troubleshooting.
This is a deeply hands-on role requiring time at the test stand, engine cell, and flight line. You will design and instrument test articles, develop ECU calibrations, and investigate failures in a fast-paced startup environment.
REQUIREMENTS:
• Bachelor's degree in Mechanical, Aerospace/Aeronautical Engineering, or related field
• U.S. Person status as defined by 22 CFR § 120.62 (U.S. citizen, lawful permanent resident, or protected asylee/refugee status) — ITAR compliance required
• 7+ years of experience in propulsion engineering with small piston engines
• Deep working knowledge of internal combustion fundamentals: thermodynamic cycles, AFR, combustion, knock, ignition systems, 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
• Fuel system design experience across full flight envelope (altitude, attitude, thermal effects)
• Experience running structured failure investigations (RCA, FMEA, FMECA, FTA) 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 fast-paced startup environment
PREFERRED QUALIFICATIONS:
• Experience with heavy fuel systems
• Master's degree in similar discipline
• Experience with sUAS or Group 1–3 unmanned aircraft propulsion
• Heavy-fuel (JP-5/JP-8) engine integration and qualification experience
• 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
