Propulsion Engineer 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.

Position Overview:

The Propulsion Engineer supports the design, analysis, and testing of propulsion systems across Zone 5's Aero product line — spanning air-launched effects, tactical interceptors, and next-generation munitions — helping ensure propulsion systems perform reliably under demanding flight, launch, and mission conditions.

You will work across the product lifecycle, from concept and trade studies through integration, test, and production, collaborating closely with Airframe, GNC, Systems Engineering, Manufacturing, and Integration & Test. Grounded in the mechanics of flight hardware — structures, thermal behavior, materials, and manufacturability — this role also advises design engineers on hardware approach and contributes to Zone 5's propulsion design standards.

Key Responsibilities:

Support the design and analysis of propulsion systems (solid primary; liquid or hybrid as programs require) across programs, from early concept through qualification.

Perform internal ballistics, structural, and thermal analysis of motor cases, nozzles, propellant grains, and igniters.

Develop and validate propulsion performance models — thrust profiles, specific impulse, and motor integration effects — and contribute models, design variables, and trade studies to vehicle-level design and multidisciplinary design optimization (MDO).

Support static fire, hot fire, and flight test campaigns: test planning, instrumentation, data reduction, and anomaly investigation.

Integrate propulsion subsystems with airframe, avionics, and launch/release mechanisms in collaboration with cross-functional teams.

Advise design engineers on hardware fundamentals — load paths, thermal protection, joints and seals, tolerancing — and partner with Manufacturing and Supply Chain on producibility, sourcing, and make/buy considerations.

Contribute to propulsion design standards for solid rocket motors, ramjets, and similar high-speed propulsion, under the direction of principal engineering.

Present technical findings at design reviews (PDR, CDR, TRR) and internal engineering discussions.

Basic Qualifications:

B.S. in Mechanical Engineering, Aerospace Engineering, or a related discipline.

3+ years of experience in propulsion system design, analysis, or test, contributing from concept through test or production.

Working knowledge of solid rocket motor design — internal ballistics, motor case, and nozzle fundamentals — with proficiency in at least one of internal ballistics, structural analysis, thermal analysis, or nozzle design.

Familiarity with static fire or hot fire test campaigns, including instrumentation and data reduction.

Programming or scripting experience (e.g., Python, MATLAB) for modeling and data analysis.

Ability to work effectively in cross-functional engineering teams; this role influences through advice and standards rather than directive authority.

US Person (ITAR) and ability to obtain a U.S. DoD Secret security clearance.

Preferred Qualifications:

M.S. in Mechanical Engineering, Aerospace Engineering, or a related discipline.

Experience with air-launched weapons, tactical missiles, or counter-UAS interceptor systems.

Experience with liquid or hybrid propulsion systems in addition to solid rocket motors.

Familiarity with energetics handling, transport, and range safety requirements.

MDO tooling experience (e.g., OpenMDAO, ModelCenter) or surrogate modeling.

Experience supporting flight test or deployed propulsion systems.

Active U.S. DoD Secret or Top Secret security clearance.

Pay range for this role

$124,000 — $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

3 weeks of paid time off each year

40 hours of sick time

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!

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 .