ESC Design Engineer – UAV Propulsion & Power Electronics

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

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