Principal Propulsion Engineer

Zone5Technologies; United States; On-site; USD 211,000 - 260,000; Full time

Benefits offered by this job

Competitive total compensation

Medical, dental, vision, life benefits

401k with company-match

4 weeks PTO

12 company holidays

Job summary

Zone 5 Technologies, a leader in unmanned aircraft systems, seeks a Principal Propulsion Engineer to own propulsion design, analysis, and qualification for solid rocket motor systems across multiple programs. The role spans concept to production, partnering with GNC, Systems Engineering, Manufacturing, and Integration & Test to deliver robust propulsion solutions.

Required 8+ years in propulsion design/test, DoD clearance eligibility, and strong internal ballistics/thermal/structural expertise;

Qualifications

• B.S. in Aerospace or Mechanical Engineering or equivalent is required.
• 8+ years of propulsion design, analysis, or test experience.
• Solid rocket motor design experience (internal ballistics, propellant grains, cases, nozzle).
• Experience owning propulsion systems from concept to flight/test/production.
• Experience with static fire/hot fire tests, instrumentation, data reduction, and anomaly investigation.
• Ability to obtain/hold US DoD security clearance (Secret or higher).
• Proficiency in modeling/data analysis with MATLAB/Python.

Responsibilities

• Own design and performance of solid rocket motor systems and propulsion subsystems across programs from concept through qualification and production.
• Lead internal ballistics, structural and thermal analysis of motor components.
• Plan, execute, and analyze static fire test campaigns and ground tests; drive root-cause investigations.
• Translate system requirements into propulsion subsystem specs in collaboration with airframe and GNC.
• Collaborate with manufacturing and supply chain to design for producibility and scale.

Skills

Troubleshooting

Programming

Cross-functional collaboration

Education

B.S. in Aerospace or Mechanical Engineering

M.S. or Ph.D. preferred

Tools

MATLAB

Python

Job description

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.

Principal Propulsion Engineer

Owns the design, analysis, and qualification of propulsion systems across Zone 5’s product line—spanning air‑launched effects, tactical interceptors, and next‑generation munitions. This role is responsible for ensuring propulsion systems perform reliably under demanding flight, launch, and mission conditions.

You will work across the full lifecycle—from concept and trade studies through design, test, qualification, and production—partnering closely with GNC, Systems Engineering, Manufacturing, and Integration & Test to deliver robust, scalable propulsion solutions.

Key Responsibilities

• Own the technical design and performance of solid rocket motor systemsand supporting propulsion subsystemsacross multiple concurrentprograms, from concept through qualification and production
• Lead internal ballistics, structural, and thermal analysis of motor cases, nozzles, propellant grains, igniters, and ignition safety components
• Drive static fire test campaigns and ground test infrastructurebydefiningtest plans, instrumentation, and acceptance criteria, and own root‑cause investigation when anomalies occur
• Translate system‑level requirements (range, thrust profile, packaging constraints, rail/tube launch loads) into propulsion subsystem specs in close coordination with airframe and GNC
• Partner with manufacturing and supply chain to design for producibility and scale — Zone 5 buildsin quantity, not justfordemonstration
• Develop and maintain technical roadmaps for propulsion product lines, including commonality and cost‑reduction strategy across programs
• Represent propulsion technical status to customers, government stakeholders, and leadership; be the face of the subsystem on your programs
• Mentor and grow propulsion engineers as the team scales under you; help build the test and design processes that don't yet exist
• Maintain rigorous documentation, safety, and regulatory compliance for energetics and propulsion systems (handling, transport, range safety)

Qualifications

Required

• B.S. in Aerospace Engineering, Mechanical Engineering, or equivalent.
• 8+ years of experience in propulsion system design, analysis, or test.
• Strong experience with solid rocket motor design, including internal ballistics, propellant/grain design, motor case, and nozzle design.
• Demonstrated ownership of propulsion systems from concept through flight test or production, not analysis in isolation.
• Experience standing up or running static fire/hot fire test campaigns, including instrumentation, data reduction, and anomaly investigation.
• Strong technical depth in at least two of: internal ballistics, structural analysis, thermal/ablation analysis, or nozzle design.
• Familiarization with energetics handling, transport, and range safety requirements.
• Programming or scripting experience (e.g., MATLAB, Python, or similar) for modeling and data analysis.
• Strong troubleshooting skills in complex propulsion test environments.
• Ability to work cross‑functionally and communicate effectively across IPTs.
• Ability to obtain and hold a U.S. DoD Secret security clearance, at minimum.

Preferred

• M.S. or Ph.D. in Aerospace Engineering, Mechanical Engineering, or related discipline.
• Experience with air‑launched weapons, tactical missiles, or counter‑UAS interceptor systems specifically.
• Experience with liquid or hybrid propulsion systems in addition to solid rocket motors.
• Experience taking a propulsion system from a startup/low‑rate environment into scaled or high‑rate production.
• Track record building or growing a propulsion team or function from the ground up.
• Familiarity with MOSA/WOSA architectures or modular weapon platforms.
• Direct relationships with solid rocket motor suppliers, energetics manufacturers, or DoD propulsion test ranges.
• Active or eligible for U.S. DoD Secret or Top Secret security clearance.

Pay Range

$211,000 — $260,000 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!

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