Engine Integration & Design

Job description

Engine Integration & Design • Lead selection, sizing, and integration of 70–100cc class 2-stroke IC engines for hybrid VTOL propulsion, balancing specific power, fuel consumption, vibration, and thermal characteristics. • Design engine mounting, vibration isolation, cooling (air/liquid), exhaust routing, and fuel delivery systems compatible with airframe and structural constraints. • Define and manage the engine-to-airframe interface control document (ICD), including mechanical, thermal, electrical, and fuel interfaces. • Work with the hybrid power architecture team to integrate the IC engine with generator/alternator units, power electronics, and battery/supercapacitor buffering. Testing & Validation • Plan and execute engine test-bench campaigns: performance mapping, specific fuel consumption, thermal endurance, and vibration/fatigue characterization. • Support accelerated life testing and mission-profile simulation for engine and associated accessories (carburetion/EFI, ignition, starter, cooling). • Conduct combinatoric test-matrix design for flight test points (throttle, altitude, duration) and analyze telemetry data to validate performance against design predictions. • Diagnose field and test anomalies (detonation, plug fouling, vibration-induced failures, thermal derating) and drive root-cause corrective actions. Qualification & Compliance • Support DGQA/CEMILAC qualification activities for the propulsion system, including test plans, environmental qualification (MIL-STD-810H), and documentation. • Contribute engine-related inputs for EMI/EMC assessments (ignition-system emissions) under MIL-STD-461 as applicable to the platform. • Maintain design and test documentation to IDDM/DAP 2020 indigenous-content and traceability requirements. Preferred / Good to Have • Prior experience on a certified or qualified aviation/UAV platform (DGCA, DGQA, CEMILAC, or equivalent). • Exposure to hybrid-electric propulsion architectures (IC engine + generator + battery/supercapacitor). • Familiarity with MIL-STD-810H environmental qualification and basic EMI/EMC concepts for ignition systems. • Experience with two-stroke engine tuning (porting, exhaust tuning, ignition mapping) in a motorsport or RC/UAV context. Key Attributes • Hands-on, build-and-test mindset with comfort working in a hardware lab and at flight-test ranges. • Strong first-principles engineering judgment and structured root-cause problem solving.