Propulsion Engineer

Position Summary

We are looking for a Propulsion Engineer to join our propulsion systems team. You will participate in the development, optimization, and testing of high-performance brushless motor systems that drive the core functionality of our UAVs. This may include ESC design, current/voltage regulation, and efficient propeller-motor integration. Your work will directly impact flight stability, energy efficiency, and system reliability.

Essential Duties and Responsibilities

• Motor Control Development
  • Participate in selection and validation of motor drivers, MOSFETs, current sensors, and gate drivers for high-efficiency operation.
• Power Electronics & ESC Design
  • Design and test ESCs tailored to drone propulsion systems with an emphasis on thermal performance, switching frequency optimization, and EMI reduction.
  • Work with PCB designers to develop compact, thermally-managed layouts for power electronics boards.
• System Integration & Performance Tuning
  • Participate in Integration of motors and controllers into UAV platforms, optimizing thrust-to-weight ratio and dynamic response.
  • Participate in Tuning PID and control loop parameters for flight stability and minimal latency.
  • Analyze power draw, efficiency curves, and torque-speed characteristics across flight envelopes.
• Testing, Validation & Failure Analysis
  • Set up and run bench and flight tests to measure thrust, RPM, current draw, and heat dissipation.
  • Use oscilloscopes, current probes, and data loggers to debug and refine system behavior.
  • Perform root cause analysis of electrical or mechanical failures in motor systems and recommend design changes.
• Cross-Functional Collaboration
  • Work closely with mechanical engineers on propeller sizing, vibration mitigation, and mount design.
  • Coordinate with flight control and embedded systems teams to ensure compatibility between propulsion and control logic.
  • Contribute to motor safety features, redundancy strategies, and startup/shutdown sequencing.

Required Qualifications

• Bachelor’s or Master’s degree in Electrical Engineering or Mechatronics.
• 4+ years of experience in BLDC motor control design and implementation.
• Strong knowledge of FOC, PWM generation, sensorless/sensored feedback systems.
• Experience on STM32, TI, or similar MCUs.
• Experience with power electronics design and hardware debugging tools (oscilloscope, logic analyzer, etc.).
• Familiarity with UAV systems or robotics platforms.

Additional Desired Qualifications

• Experience with high-frequency switching and thermal design in compact UAV ESCs.
• Familiarity with drone-specific motor testing, thrust stands, and performance tuning methods.
• Simulation experience using MATLAB/Simulink or PLECS for motor dynamics.
• Knowledge of EMI/EMC design practices and compliance testing.

Physical Requirements and Working Conditions

• Hands-on lab testing, prototyping, and field validation.
• Occasional outdoor flight testing and iterative hardware development.
• Team-based development in an agile engineering environment.

Background Check

This position will require successfully completing a post-offer background check. Qualified candidates with a criminal history will be considered and are not automatically disqualified, consistent with federal and state law.

EEO and ITAR/EAR Work Authorization Disclosure

Red Cat Holdings provides equal employment opportunities (EEO) to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. This position requires direct or indirect access to hardware, software, technology or technical data controlled under the International Traffic in Arms Regulations (ITAR) and the Export Administration Regulations (EAR). Successful candidates for positions subject to ITAR/EAR restrictions must provide proof of U.S. Citizenship or Permanent Residence and must not require sponsorship for export-restricted work authorization.

E-Verify

The company participates E-Verify ensure eligibility for employment and compliance with Right to Work rules.

Compensation: Salary plus generous annual equity package and potential bonuses.