FLIGHT TEST ENGINEER - JOB #1136
Reports To: Director, Flight Operations & Flight Test
Status: Full-Time, On-Site, Salary, Exempt
Location: Menominee, MI
Pay Range: $70,000–$110,000 per year
POSITION SUMMARY
The Flight Test Engineer is a member of the Flight Test Department and supports the planning, preparation, execution, analysis, and documentation of aircraft ground- and flight-test activities. The position supports the complete flight-test lifecycle, from initial test-request evaluation and test-plan development through test execution, data analysis, reporting, and closure.
This position may be filled at a developing or experienced level. A developing engineer will work under the guidance of senior flight-test personnel and progressively assume responsibility for assigned tests as capability is demonstrated. An experienced candidate may independently lead assigned test activities, mentor developing personnel, and serve as a technical focal point for complex development or certification work.
Placement within the published range will reflect relevant experience and demonstrated independence. The upper range is reserved for candidates able to lead complex flight-test or certification work and mentor others.
The Flight Test Engineer works closely with flight-test pilots, design engineers, certification personnel, maintenance, quality, and other technical groups to ensure testing is conducted safely and efficiently with clearly defined objectives, configurations, procedures, data requirements, and acceptance criteria. Testing may support research and development, product improvement, troubleshooting, production, continued airworthiness, and FAA certification programs.
GENERAL DESCRIPTION OF TASKS
- Support the planning, coordination, and execution of aircraft ground and flight tests for development, certification, troubleshooting, continued airworthiness, production, and other approved company programs.
- Review test requests and help define objectives, aircraft configuration, test conditions, procedures, data requirements, hazards, acceptance criteria, and deliverables.
- Develop and maintain flight-test plans, flight cards, test procedures, test reports, and flight-test inputs to certification and compliance documentation, with the level of review appropriate to the assignment and the engineer’s experience.
- Coordinate with pilots, engineering, maintenance, quality, instrumentation personnel, and program stakeholders.
- Support pre-test planning, pre-flight briefings, and post-flight debriefings.
- Program, configure, and operate data acquisition systems and related test equipment. Training may be provided for company-specific systems and methods.
- Support the selection, layout, installation, checkout, calibration, and maintenance of instrumentation, including sensors, accelerometers, strain gauges, and associated wiring.
- Reduce, analyze, and document test data.
- Identify data-quality issues, limitations, trends, and conclusions and clearly communicate results to technical and program stakeholders.
- Determine, verify, and document aircraft loading, weight, center of gravity, and test configuration for assigned ground- and flight-test activities.
- Coordinate the design and use of test fixtures, specialized test equipment, and test facilities with the appropriate engineering and technical groups.
- Participate in safety-of-flight reviews, test-readiness reviews, design reviews, and other engineering reviews requiring flight-test input.
- Support test-article conformity, certification test readiness, TIA testing, and other assigned FAA certification activities.
- Coordinate with FAA personnel, FAA designees, and other regulatory representatives when directed and in coordination with Certification Engineering and program leadership.
- Prepare and maintain test records, data packages, configuration records, and technical inputs supporting Type Inspection Reports and other certification documentation.
- Contribute to the continued development of standardized test methods, flight cards, readiness processes, configuration-control practices, data-management methods, safety reviews, and technical reporting standards.
- Perform other flight-test-related duties as assigned and progressively lead assigned test activities as experience and capability are demonstrated.
REQUIRED QUALIFICATIONS
- Bachelor’s degree in Aerospace, Mechanical, Electrical, Systems, or another related engineering field.
- Minimum of one year of engineering or technical test experience in aerospace or another technical field. Relevant co-op, internship, laboratory, development-test, or hands-on engineering experience may be considered based on scope and responsibility.
- Foundational knowledge in one or more relevant technical areas, such as aircraft structures, systems, dynamics, aerodynamics, powerplants, instrumentation, data acquisition, or engineering data analysis, with the ability to develop broader flight-test knowledge.
- Experience preparing technical procedures, engineering documentation, test records, or reports.
- Hands-on experience with, or demonstrated ability to learn, instrumentation, sensors, wiring, data acquisition systems, test equipment, and basic engineering analysis tools.
- Strong analytical, problem-solving, organizational, and written and verbal communication skills.
- Ability to work safely and effectively in a cross-functional team, manage multiple assignments, and follow controlled test and configuration processes.
- Proficiency with Microsoft Office applications and basic CAD experience using SolidWorks or similar software.
PREFERRED QUALIFICATIONS
- Three or more years of aerospace engineering, development-test, or flight-test experience, particularly experience independently planning and leading complex test activities.
- Flight Test Engineer or Flight Test Analyst experience involving rotorcraft systems, handling qualities, vibration, dynamics, performance, or certification.
- Experience with data acquisition and analysis tools such as LabVIEW, National Instruments hardware, MATLAB, Python, or similar systems.
- Experience planning and installing instrumentation, strain gauges, sensors, and associated wiring, including calibration and data-quality verification.
- Knowledge of FAA regulations, 14 CFR Part 27 certification processes, test-article conformity, TIA testing, and compliance documentation.
- Flight Test Pilot or other relevant flight-operations experience.
- FAA Designated Engineering Representative designation or experience supporting delegated certification work.
- Demonstrated ability to mentor others, improve test processes, and function as a technical lead.
PHYSICAL REQUIREMENTS
- Ability to work in office, hangar, laboratory, and flight-line environments, including around operating aircraft and test equipment.
- Ability to access aircraft interiors, test equipment, and elevated work areas and perform hands-on instrumentation and inspection tasks.
- Ability to occasionally lift and carry up to 30 pounds.
- Ability to travel occasionally in support of certification, testing, supplier, or customer activities.
- Ability to work extended or nonstandard hours when required to support flight-test schedules, weather windows, and certification milestones.
