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Key Responsibilities and Required Skills for Flight Test Engineer

💰 $95,000 - $185,000

EngineeringAerospaceAviationResearch & Development

🎯 Role Definition

Are you ready to be at the forefront of aerospace innovation? As a Flight Test Engineer (FTE), you are the crucial link between aircraft design and real-world performance. You will be responsible for the entire lifecycle of aircraft testing, from initial planning and safety analysis to real-time mission control and post-flight data evaluation. This role requires a unique blend of deep technical knowledge, rigorous analytical skills, and unwavering composure under pressure. You will work hand-in-hand with test pilots, design engineers, and technicians to push the boundaries of flight, validate cutting-edge technology, and ultimately ensure the safety and airworthiness of the next generation of aircraft. If you have a passion for aviation and a drive to solve complex engineering challenges, this is the career for you.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Aerospace, Mechanical, or Electrical Engineering Graduate
  • Systems Engineer
  • Aircraft Maintenance Technician (with an engineering degree)

Advancement To:

  • Senior or Principal Flight Test Engineer
  • Flight Test Program Manager
  • Chief Engineer / Technical Fellow
  • Test Pilot (requires significant additional flight training)

Lateral Moves:

  • Systems Integration Engineer
  • Certification Engineer
  • Project/Program Engineer

Core Responsibilities

Primary Functions

  • Develop comprehensive flight and ground test plans, test schedules, and detailed test procedures in collaboration with design, systems, and safety engineering teams to ensure all test objectives are met.
  • Conduct pre-flight and post-flight briefings with test pilots, engineers, and maintenance personnel to ensure clear communication and alignment on test objectives and outcomes.
  • Act as a Test Conductor in a control room environment, directing the flight crew through test maneuvers and monitoring real-time telemetry data for safety of flight and test success.
  • Perform detailed safety and hazard analysis for test operations, participating in Technical Review Boards (TRB) and Safety Review Boards (SRB) to secure flight readiness approvals.
  • Define and coordinate aircraft instrumentation requirements with instrumentation engineers to ensure critical data parameters are accurately captured during ground and flight testing.
  • Analyze in-depth post-flight data using tools like MATLAB or Python to verify system performance, validate aerodynamic models, identify anomalies, and prepare detailed test reports.
  • Author and publish formal flight test reports and technical memorandums that clearly document test results, conclusions, and recommendations for program leadership and certification authorities.
  • Troubleshoot and investigate system anomalies observed during testing, working closely with design teams to perform root cause analysis and recommend corrective actions.
  • Support the development and verification of Aircraft Flight Manuals (AFM), emergency procedures, and operational limitations based on empirical flight test data.
  • Manage and maintain the configuration of the test aircraft to ensure it accurately reflects the engineering design and intended state for each specific test campaign.
  • Plan and execute critical ground testing activities, including structural tests, electromagnetic interference/compatibility (EMI/EMC) tests, and integrated systems checkouts.
  • Serve as the primary engineering decision-maker during test missions, providing real-time guidance on test point execution, data quality, and critical safety-of-flight judgments.
  • Collaborate with regulatory agencies (e.g., FAA, EASA) to develop certification test plans and demonstrate compliance with all applicable airworthiness standards.
  • Operate and configure data acquisition systems and telemetry streams, ensuring high data integrity from the on-board sensor to the final ground-based data product.
  • Evaluate aircraft handling qualities, performance characteristics, and the functionality of complex integrated systems such as avionics, fly-by-wire flight controls, and propulsion systems.
  • Participate in the flight readiness review (FRR) process, confidently presenting test plans and risk assessments to senior management and technical experts.
  • Act as an on-board flight test engineer (FTE) on applicable aircraft to gather data, observe system behavior firsthand, and provide real-time crew coordination.

Secondary Functions

  • Support the calibration of aircraft air data systems and other critical sensors through dedicated flight test maneuvers and subsequent data analysis.
  • Develop and refine flight test techniques and methodologies to continuously improve the efficiency, safety, and effectiveness of the flight test program.
  • Provide flight test engineering expertise during design reviews to ensure new systems are architected with testability and verification requirements in mind.
  • Create and maintain the statement of work, test resource definitions, and schedules for complex flight test campaigns to ensure on-time and on-budget execution.

Required Skills & Competencies

Hard Skills (Technical)

  • Proficiency in data analysis and programming languages such as MATLAB, Python, or LabVIEW.
  • Strong knowledge of aircraft systems, including avionics, flight controls, hydraulics, and propulsion.
  • Deep understanding of aerodynamics, aircraft performance, stability, and control principles.
  • Experience with flight test instrumentation, data acquisition systems, and telemetry.
  • Familiarity with FAA and EASA certification regulations (e.g., 14 CFR Part 23, 25, 27, 29).
  • Experience authoring and executing formal test plans and procedures.
  • Competency in real-time telemetry monitoring and control room operations.

Soft Skills

  • Exceptional written and verbal communication skills, with the ability to convey complex technical information clearly and concisely.
  • Strong analytical and methodical problem-solving abilities, especially under pressure.
  • Meticulous attention to detail and an uncompromising commitment to safety.
  • Excellent teamwork and interpersonal skills for collaborating in a multi-disciplinary environment.
  • Proactive risk management and hazard assessment mindset.
  • Adaptability and flexibility to work in a dynamic, fast-paced, and evolving test environment.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor of Science degree in an engineering discipline from an accredited university.

Preferred Education:

  • Master of Science degree in an engineering discipline.
  • Completion of a recognized Test Pilot School (TPS) curriculum for engineers.

Relevant Fields of Study:

  • Aerospace / Aeronautical Engineering
  • Mechanical Engineering
  • Electrical Engineering

Experience Requirements

Typical Experience Range: 2-10+ years of relevant experience in an aerospace or testing environment.

Preferred:

  • Direct, hands-on experience in the flight testing of experimental or developmental aircraft (fixed-wing, rotorcraft, or eVTOL).
  • Experience with aircraft certification programs and working with regulatory bodies.
  • A private pilot license or other flight experience is highly desirable.
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