Senior Flight Test Engineer

Job Title: Senior Flight Test Engineer

Company: BonV Technology Pvt. Ltd.

Industry: Aerial Mobility Solutions

Department: Business Development

Location: Bhubaneswar (On-site)

Employment Type: Full-Time

Role Overview

The Senior Flight Test Engineer (UAV) will lead end-to-end flight-testing activities for advanced fixed-

wing, VTOL, and multirotor UAV platforms developed in the R&D division. The role requires deep

expertise in test planning, UAV performance evaluation, data analysis, safety management, and

cross-functional coordination to support rapid prototyping and iterative product development.

You will be responsible for ensuring that every UAV platform meets safety, reliability, and

performance goals as per R&D requirements and regulatory standards (DGCA, MoD, internal SOPs).

Key Responsibilities

A. Flight Test Planning & Execution

Develop detailed Flight Test Plans (FTP), test cards, and risk assessments for new UAV prototypes and mission profiles.

Execute test flights in Stabilize, AltHold, Loiter, Auto, and advanced modes including transition (VTOL) and high-speed cruise.

Perform envelope expansion, performance flights, endurance tests, and payload integration tests.

Lead ground tests: motor thrust bench testing, vibration analysis, compass/magnetometer calibration (Mag-Fit), ESC/Powertrain tests, and failsafe validation.

Ensure strict compliance with internal flight test SOPs and national regulations.

Collect, log, and analyze flight data (ArduPilot logs, PX4 logs, high-speed telemetry).

Debug issues related to PID tuning, vibration, power system behavior, barometer/IMU anomalies, GPS/RTK performance, etc.

Prepare structured test reports, NCRs, and RCAs with actionable recommendations to design, avionics, and software teams.

Provide flight behavior insights for improving control algorithms and performance models.

B. Cross-Functional Collaboration

Work closely with system engineering, avionics, mechanical design, propulsion, and embedded software teams.

Support integration of new sensors, payloads, autopilot updates, and firmware changes.

Provide real-world feedback to R&D teams for aerodynamic improvements, electronics bay design, EMI/EMC corrections, and reliability enhancements.

Mandatory Skills & Requirements:

A. Technical Skills

Strong hands-on experience with ArduPilot/PX4, Cube Orange/Black, Pixhawk-based flight controllers.

Expertise in PID tuning, notch filters, vibration isolation, and autopilot configuration.

Proficiency in mission planning software (Mission Planner/QGroundControl).

Solid understanding of aerodynamics, propulsion systems, ESCs, motors, propellers, and high-voltage power systems.

Ability to evaluate performance parameters: endurance, thrust, stability margins, airspeed, drag, attitude response.

Familiarity with data analysis tools (Mission Planner, Matlab/Python preferred).

B. Operational Skills

Experience flying heavy-lift UAVs (50200 kg class) and mid-size multirotor/fixed-wing drones.

Ability to perform emergency handling, failsafe recovery, and controlled decision-making under pressure.

Strong command of UAV test ranges, DGCA guidelines, and risk management practices.

Preferred Qualifications

Bachelor's/Master's degree in Aerospace Engineering, Electronics, Mechatronics, Robotics, or related field.

Prior experience in Defence UAV R&D, rapid prototyping labs, or high-end flight-testing teams.

Experience with adaptive control algorithms, real-time telemetry, or AI-based flight control (bonus).

Certification in UAV Safety, Test Pilot training, or DGCA-approved Remote Pilot License

(desirable).

BonV Aero is an equal opportunity employer. We look forward to welcoming enthusiastic individuals eager to contribute to a growing and dynamic environment.

Join BonV Technology and be part of a team that is shaping the future of aerial technology. Apply now to contribute your expertise and passion to our innovative journey