Position: Senior Flight Test Engineer
Department: Systems
Location: Bhubneshwar
Employment Type: Full-time
Experience: 3–5+ years in UAV Flight Testing & Validation
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
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).
Operational Skills
- Experience flying heavy-lift UAVs (50–200 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).
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.
