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 T…