ESC Design Engineer

Malloy Aeronautics Ltd.; Maidenhead; On-site; GBP 60,000 - 90,000; Full time

Benefits offered by this job

Alternate Fridays off (9‑day fortnight

Share Incentive Plan

5% employer pension

Annual incentive bonus

Enhanced maternity/paternity leave

20 days annual leave + Christmas break

Healthcare plan

Mental health support

Cycle to Work

Armed Forces Covenant

Job summary

Malloy Aeronautics Ltd. is seeking an ESC Design Engineer to advance UAV propulsion systems. You will design ESC hardware for high-current motors, implement control algorithms, and ensure thermal, electrical, and EMI/EMC performance.

This role demands hands-on design, testing, and integration within a team that delivers cutting-edge aerospace tech. Ideal candidates bring motor control expertise, power electronics knowledge, and a practical approach to testing, documentation, and

Qualifications

• Strong knowledge of motor control theory and ESC topologies.
• Deep understanding of power electronics components.
• Understanding of thermal management and EMI mitigation for high-power systems.
• Awareness of UAV propulsion system requirements and constraints.
• Knowledge of wide band gap devices (SiC, GaN).

Responsibilities

• Design and develop ESC hardware for brushless DC and PMSM motors, including power stage, gate drivers, and protection and control circuits.
• Define and implement control algorithms (e.g. FOC, trapezoidal, sensorless) with embedded software teams.
• Select and validate components to meet thermal, electrical, and EMI/EMC constraints for UAVs.
• Conduct simulations to evaluate circuit behaviour, efficiency, and thermal performance.
• Create schematics and PCB layouts optimised for high-current, high-frequency switching.
• Validate ESC performance through bench tests, HIL setups, and full propulsion system integration.
• Support fault diagnosis and design improvements in R&D and production contexts.
• Work with thermal and mechanical engineers on heatsinking, packaging, and environmental protection.
• Document design decisions, test results, and compliance evidence.
• Contribute to design-for-manufacture and design-for-assembly improvements.
• Design and development of ESC test systems.

Skills

Motor control theory

ESC topologies

Power electronics

Thermal management

EMI mitigation

PCB layout

UAV propulsion requirements

Wide bandgap devices

Tools

Altium

KiCad

Job description

Join the Team Building the Future of Flight

Are you looking for an opportunity to make a real impact, take on exciting challenges, and be part of a team that's shaping the future of aviation?

At Malloy Aeronautics, you'll play a key role in helping us develop innovative technology that's changing the way the world moves.

Who are we?

We're on a mission to revolutionise unmanned flight. At Malloy Aeronautics, we develop advanced heavy-lift UAVs for both defence and commercial applications.

What sets us apart is our in-house approach. From design and engineering to manufacturing and testing, the majority of our work happens under one roof in Berkshire, allowing us to innovate quickly, maintain exceptional quality, and bring ideas to life faster.

For our teams, that means hands-on involvement, real ownership, and the opportunity to help shape the future of aviation.

What are we looking for?

Malloy Aeronautics is looking for an ESC Design Engineer with experience in power electronics and motor control to support the development of advanced UAV propulsion systems. This role is ideal for an engineer who enjoys hands-on design, testing and integration, and wants to help deliver innovative aerospace technology.

Ability to hold Security Clearance - 5 years residence in the UK

What You'll Being Doing (but Not Limited Too)

• Design and develop ESC hardware for brushless DC and PMSM motors, including power stage, gate drivers, and protection and control circuits
• Define and implement control algorithms (e.g. FOC, trapezoidal, sensorless) in collaboration with embedded software teams
• Select and validate components to meet thermal, electrical, and EMI/EMC constraints for UAV applications
• Conduct simulations (e.g. SPICE, ANSYS) to evaluate circuit behaviour, efficiency, and thermal performance
• Create schematics and PCB layouts optimised for high-current, high-frequency switching applications
• Validate ESC performance through bench tests, HIL setups, and full propulsion system integration
• Support fault diagnosis, root cause analysis, and design improvements in both R&D and production contexts
• Work with thermal and mechanical engineers to define heatsinking, packaging, and environmental protection solutions
• Document design decisions, test results, and compliance evidence for quality and traceability
• Contribute to design-for-manufacture and design-for-assembly improvements for ESC production scaling
• Design and development of ESC test systems

Essential Skills And Experiences

• Strong knowledge of motor control theory and ESC topologies (e.g. field-oriented control, BLDC 6-step trapezoidal control)
• Deep understanding of power electronics components (MOSFETs, gate drivers, capacitors, inductors, current sensors)
• Understanding of thermal management, EMI mitigation, and PCB layout strategies for high-power systems
• Awareness of UAV propulsion system requirements and constraints (weight, efficiency, safety)
• Good understanding of wide band gap devices (e.g. SiC, GaN)

Desired Skills And Experiences

• Proficient in schematic capture and PCB design using tools such as Altium or KiCad
• Skilled in simulating and analysing power electronics systems for performance and reliability
• Hands-on experience with laboratory testing, using oscilloscopes, power analysers, and motor rigs
• Clear technical communicator capable of producing thorough documentation and test reports
• Detail-oriented, methodical, and safety-conscious in working with high-voltage and high-current systems
• Able to collaborate across disciplines and support real-world system integration and troubleshooting
• Writing risk assessments to determine best working practices
• Task flexibility - adaptive planning

Benefits You May Be Eligible For

• Alternate Fridays off with our 9-day fortnight
• BAE Systems Share Incentive Plan
• 5% employer pension contribution
• Annual collective incentive bonus scheme
• Enhanced family leave with 6 months' full-pay maternity leave and 4 weeks' full-pay paternity leave
• 20 days' annual leave, increasing with service, plus a 3-day Christmas shutdown
• Company sick pay
• Healthcare Cash Plan with Virtual GP access, dental and optical support, plus free cover for dependent children up to age 24
• Mental health and wellbeing support available 24/7
• Cycle to Work Scheme
• Proud supporter of the Armed Forces through our Bronze Armed Forces Covenant commitment.

Malloy Aeronautics employees will be subject to both security and export control restrictions. These restrictions mean that factors including your nationality, any previous nationalities you have held, and your place of birth may limit those roles you can perform for the organisation.

We're committed to building an inclusive workplace where everyone feels valued and supported. We know that a diversity of backgrounds, perspectives and experiences strengthens our teams and is vital to the work we do.

Please be aware that many roles at Malloy Aeronautics are subject to both security and export control restrictions. These restrictions mean that factors such as your nationality, any nationalities you may have previously held, and your place of birth can restrict the roles you are eligible to perform within the organisation. All applicants must as a minimum achieve Baseline Personnel Security Standard. Many roles also require higher levels of National Security Vetting where applicants must typically have 5 to 10 years of continuous residency in the UK depending on the vetting level required for the role, to allow for meaningful security