Aerodynamics Engineer, Propulsion Integration (III/IV)

At Zone 5 Technologies, we're redefining what's possible in unmanned aircraft systems. Our team of engineers and innovators is developing cutting-edge autonomous solutions that push the boundaries of UAS technology - solving complex challenges that matter.

We're building the future of UAS capabilities, and we're looking for exceptional talent to join us. If you're driven by hard problems, energized by rapid innovation, and ready to make an impact on next-generation flight systems, you belong here.

We are seeking an Aerodynamics Engineer with propulsion design and integration experience to join our Aerodynamics team. Our ideal candidate will have demonstrable experiences within the field of airbreathing propulsion integration and design, analysis, and optimization in advanced Unmanned Aerial Systems (UAS).

We are looking for candidates that embody a solid understanding of fluid dynamics, aerodynamic design, engine inlet and exhaust design, mechanical integration, and aircraft performance. The ideal candidate will have demonstrated use of tools in their tool belt ranging from hand, 1-D/2-D calculations, computational methods, wind tunnels, and flight testing of physical hardware in validating their designs and meeting their objectives. This individual avoids siloing and consciously balances priority and speed with scaling products, and they have a mission focused on supporting our customers.

Key Responsibilities:

• Responsible for aerodynamic design of turbine engine flow paths (inlet, exhaust, secondary flows) on high performance UAV.

• Conduct low, mid, and high fidelity CFD simulations to assess aerodynamic, mechanical, thermal, and aircraft performance impact of designs.

• Develop and validate aerodynamic models using combinations of CFD, wind tunnel testing, and/or flight test data.

• Collaborate with multidisciplinary teams (structures, propulsion, controls, systems engineering) to integrate aerodynamic insights into the overall design.

• Assist in the development of bench test, wind tunnel test, and flight test plans and data reduction and analysis.

• Ownership of simulation propulsion modules and modeling fidelity.

• Working proficiency and practical understanding of engine performance and modeling.

• Preparing technical reports, presentations, and design documentation.

• Present findings to key stakeholders and internal/external customers.

Qualifications:

• A Masters's degree in Aerospace Engineering, Mechanical Engineering, or related field is strongly preferred. Bachelor’s degree plus relevant experience required.

• 3-5 years of inlet/duct design and solving problems in aero-propulsion and integration of aerodynamics for aircraft and/or UAVs.

• Demonstrable experience building and maintaining low and mid fidelity aerodynamic modeling tools.

• Applied experience with a Navier-Stokes based CFD tools (e.g., ANSYS Fluent, STAR-CCM+, OpenFOAM, Fun3D) including geometry preparation, mesh generation, and simulation debugging. .

• Experience with data visualization tools, e.g. MATLAB & Python, Tecplot, ParaView and working in a version control environment, e.g. git.

• Industrial wind tunnel testing: model design, techniques, instrumentation, and data reduction.

• Applied designs in subsonic, transonic, and high-speed aerodynamics.

• U.S. Citizenship or equivalent status required for defense-related work.

• Security clearance (or eligibility) is a plus.

Bonus Skills and Applied Experiences:

• Expertise in Inlet/Exhaust Aerodynamic design and surfacing.

• Aerodynamic bookkeeping of inlet installation effects and losses (ram, drag, moments, etc.)

• Engine performance modeling via common industry tools (NPSS, GasTurb, AxSTREAM, etc.)

• Expertise in inlet distortion and inlet/compressor interactions

• Rocket propulsion design and simulation.

• Flight testing, telemetry analysis, and / or real-time simulation environments.

• Working knowledge of applicable industry standards (MIL-STD, SAE ARP, etc.)

For candidates based in San Luis Obispo, California, the annual base salary range for this role is $120,000 - $190,000/year USD. The final compensation package will be determined based on factors including but not limited to experience, skills, qualifications, and internal pay equity.

Pay range for this role
$115,000—$175,000 USD

What's in it for you:

Benefits:

• Competitive total compensation package

• Comprehensive benefit package options include medical, dental, vision, life, and more.

• 401k with company-match

• 4 weeks of paid time off each year

• 12 annual company holidays

Why Join Zone 5 Technologies?

• Innovative Environment: Work on cutting-edge technology that is shaping the future of defense and aerospace.

• Collaborative Culture: Join a team of passionate professionals dedicated to pushing the boundaries of what’s possible.

• Career Growth: Opportunities for professional development and career advancement.

If you are passionate about unmanned aircraft technology and want to be a part of a dynamic and growing company, we would love to hear from you. Apply today and join the Zone 5 Technologies team!

Note about our Texas roles: we are in the process of opening a location on the mid-west side of the DFW metro region. Roles in Texas will initially work remotely and then be expected to be onsite when that location opens in 2026.

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.

Zone 5 Technologies is a federal contractor and participates in E-Verify to confirm employment eligibility. As required by law, we will verify the identity and employment authorization of all new employees using the E-Verify system. Learn more about your rights and responsibilities under E-Verify: https://www.e-verify.gov.