Propulsion Engineer IV New

Zone 5 Tech; Northern (KY); On-site; USD 124,000 - 175,000; Full time

Benefits offered by this job

Medical, dental, vision

Life insurance

401k with match

Paid time off

Holidays

Job summary

Zone 5 Technologies in the United States is seeking a Propulsion Engineer to support design, analysis, and testing of propulsion systems across Aero products, including air-launched effects and missiles. You will work across the product lifecycle from concept through production, collaborating with Airframe, GNC, and Manufacturing.

The role emphasizes solid rocket motor design, internal ballistics, structural and thermal analysis, and propulsion performance modeling.

Qualifications

• BS in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• 3+ years of experience in propulsion system design, analysis, or test.
• Proficiency in at least one of internal ballistics, structural analysis, thermal analysis, or nozzle design.
• Familiarity with static fire or hot fire test campaigns and data reduction.
• Programming or scripting experience (Python, MATLAB).
• Ability to work in cross-functional teams; influence through standards.
• US Person (ITAR) and ability to obtain DoD clearance.

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 propulsion performance models—thrust profiles, specific impulse, and motor integration effects—and contribute models and trade studies to system design.
• Support static fire, hot fire, and flight test campaigns: planning, instrumentation, data reduction, and anomaly investigation.
• Integrate propulsion subsystems with airframe, avionics, and launch/release mechanisms with cross-functional teams.
• Advise design engineers on hardware fundamentals—load paths, thermal protection, joints and seals, tolerancing—and coordinate with Manufacturing on producibility.
• Contribute to propulsion design standards for solid rocket motors and related systems.
• Present findings at design reviews (PDR, CDR, TRR) and internal discussions.

Skills

Propulsion design

Internal ballistics

Thermal analysis

Solid rocket motor design

Python MATLAB

Cross-functional teamwork

Education

BS in Mechanical or Aerospace Engineering

MS in Mechanical/Aerospace Engineering (preferred)

Tools

OpenMDAO

ModelCenter

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.

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 andvalidatepropulsion 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,jointsand 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 — withproficiencyin 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 orTop Secretsecurity clearance.

Pay range for this role

$124,000 - $175,000 USD

What\'s in it for you:

• 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!

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