Key Responsibilities and Required Skills for Jet Engine Engineer

🎯 Role Definition

As a Jet Engine Engineer you will lead the technical development, testing, validation and sustainment of commercial and military gas turbine engines and propulsion systems. You will apply expertise in thermodynamics, aero-thermal performance, structural mechanics, rotordynamics, materials (nickel-based superalloys, CMCs), combustor and turbine design, and control-system integration (FADEC). This role requires hands-on test program experience, strong analytical skills (CFD/FEA), CAD proficiency, and the ability to drive engine certification and product readiness with OEMs, MROs and regulators (FAA/EASA).

Key search terms: jet engine engineer, gas turbine engineer, propulsion engineer, turbine engine design, aero-thermal, combustor, compressor, rotordynamics, FADEC, engine testing, CFD, FEA, materials engineering, certification.

📈 Career Progression

Typical Career Path

Entry Point From:

Graduate Aerospace / Mechanical Engineer (Propulsion track)
Turbine Engine Test Engineer or Engine Systems Engineer
Mechanical Design Engineer with CAD experience in CATIA or NX

Advancement To:

Senior Jet Engine Engineer / Lead Propulsion Engineer
Engine Program Manager or Chief Propulsion Engineer
Principal Engineer, Technical Fellow, or Director of Propulsion Engineering

Lateral Moves:

Systems Engineer (aircraft propulsion integration)
Reliability & Maintainability (R&M) Engineer
Manufacturing / Test Operations Engineering

Core Responsibilities

Primary Functions

Lead detailed design and optimization of compressor, combustor, turbine and nozzle components to meet performance, efficiency, emissions and durability targets while balancing manufacturability and cost.
Develop and execute aero-thermal analyses including steady and unsteady CFD studies to quantify flow fields, temperature distributions, cooling air requirements, and combustion dynamics for axial-flow gas turbines.
Perform structural and thermo-mechanical analysis (FEA) of rotating and stationary components to evaluate stresses, creep, fatigue life, and to support life-limited parts decisions using tools such as NASTRAN, Abaqus or ANSYS.
Define and analyze rotordynamics and vibration characteristics of shafts, discs and assemblies; design bearing systems, seals and dampers to control critical speeds and ensure safe margins for resonance and whirl.
Generate and maintain detailed 3D CAD models, product definition, GD&T and manufacturing deliverables in CATIA V5/V6, Siemens NX or equivalent to support tooling, assembly and production transfer.
Specify materials and thermal barrier coatings (TBCs) for hot-section parts (blades, vanes, combustor liners) including selection of nickel-based superalloys, CMET/CMC solutions, and coating/process controls to extend life and reduce oxidation/erosion.
Lead engine test campaigns: plan instrumentation, define test objectives, oversee rig and full-scale engine tests, analyze time-domain and frequency-domain data, and produce test reports that drive design iterations and certification evidence.
Develop and validate engine performance models (thermodynamic cycle analysis) to predict thrust, specific fuel consumption (SFC), bleed schedules, and operability maps across flight envelopes and ground conditions.
Create and maintain engine control logic and FADEC interface requirements; coordinate with controls engineers to validate transient behavior, surge/stall margins, and fault handling strategies.
Drive root cause investigations for in-service failures or test anomalies: lead FMEA/FMECA, inspection campaigns, metallurgical analysis, and corrective action implementation with suppliers and maintenance teams.
Prepare engineering substantiation for certification packages to regulators (FAA, EASA) including compliance matrices, test evidence, structural substantiation, and Environmental Control documentation.
Manage supplier technical performance for castings, forgings, blisks, coatings and precision-machined components; define technical specifications, perform supplier audits, and lead non-conformance resolution.
Define inspection and non-destructive testing (NDT) requirements (eddy current, ultrasonic, borescope, radiography) and collaborate with quality and MRO teams to implement serviceability criteria and overhaul limits.
Apply life and reliability analysis methodologies including crack growth, creep-fatigue interaction, and damage tolerance to set retirement-for-cause and safe-life boundaries for rotating hardware.
Lead cost-reduction and manufacturability initiatives such as design for manufacturability/assembly (DFM/DFA), additive manufacturing pilots for complex geometries, and supplier consolidation strategies.
Develop and maintain detailed technical documentation: drawing packages, CALS data, job cards, service bulletins, and maintenance manuals to support production and in-service support.
Interface with interdisciplinary teams (airframe integration, systems, avionics, environmental) to ensure propulsion integration, inlet/exhaust packaging, thermal management, and nacelle compatibility.
Mentor junior engineers and interns; run design reviews, provide technical guidance, and foster knowledge transfer across propulsion engineering teams.
Implement and maintain engineering change control (ECO/ECN) processes; evaluate configuration changes, cost/weight impacts, and update certification baselines.
Conduct performance and operability trade studies including weight vs. efficiency, emissions vs. cost, and noise abatement measures to meet customer and regulatory requirements.
Utilize data analytics (MATLAB, Python, SQL) to process telemetry and test data, create dashboards, and extract insights that drive predictive maintenance, life extension, and reliability improvements.
Ensure health, safety and environmental compliance in engine test cells, manufacturing, and lab operations; lead hazard analyses (HAZOP, HAZID) associated with fuel systems and high-temperature test programs.
Collaborate with marketing, sales and aftermarket teams to define new engine features, sustainment packages, and customer retrofit/upgrade solutions that enhance fleet value and reduce operating cost.

Secondary Functions

Support ad-hoc engineering investigations and rapid-response troubleshooting for in-service engine events, including borescope program reviews and field technical support.
Contribute to continuous improvement initiatives across the propulsion organization, implementing lessons learned from test campaigns and service reports.
Coordinate with certification and regulatory affairs to prepare responses to airworthiness directives (ADs), service bulletins (SBs), and type certificate changes.
Support supplier onboarding and qualification activities, including build-to-print verification, first article inspections (FAI), and process capability studies (Cp/Cpk).
Provide technical input to procurement for long-lead items, tooling, and fixtures; review supplier proposals for technical compliance and risk.
Participate in cross-functional product development sprints, stage-gate reviews, and program milestone presentations for internal stakeholders and customers.
Assist in estimating engineering labor, test scopes, materials and capital equipment for new engine programs and sustainment contracts.
Lead or participate in internal and external technical audits, ensuring adherence to AS9100, NADCAP, and relevant quality standards.
Deliver technical briefings to customers, OEM partners and regulatory representatives explaining design rationale, test results and mitigation plans.
Promote knowledge sharing by organizing technical seminars, writing whitepapers on aero-thermal innovations, and contributing to patent or publications when applicable.

Required Skills & Competencies

Hard Skills (Technical)

Gas turbine thermodynamics and performance modeling (cycle analysis, performance maps, bleed and control schedules).
Computational Fluid Dynamics (CFD) for turbomachinery and combustor flow (ANSYS Fluent, CFX, STAR-CCM+, or equivalent).
Finite Element Analysis (FEA) for thermal-stress and fatigue analysis (NASTRAN, Abaqus, ANSYS Mechanical).
Rotordynamics and vibration analysis tools and methodologies (critical speed analysis, Campbell diagrams, bearing modeling).
3D CAD and product definition (CATIA V5/V6, Siemens NX, SolidWorks) and familiarity with PLM systems (Teamcenter, ENOVIA).
Engine control systems: FADEC requirements, transient modeling, and control-law validation (Simulink, Python-based test benches).
Materials engineering for high-temperature alloys, coating systems and additive manufacturing qualification.
Engine test planning, instrumentation, data acquisition (DAQ) systems and post-test data reduction/interpretation.
Structural durability, damage tolerance, life assessment, FMECA/FMEA and reliability analyses.
NDT techniques and inspection planning (borescope, eddy-current, ultrasonic, radiography).
Certification and regulatory experience (FAA, EASA, Part 33/21 processes, DER interactions).
Manufacturing processes for aero components: forging, casting, precision machining, blisk/impeller manufacturing.
Programming and data analysis: MATLAB, Python, SQL for telemetry, telemetry reduction, and prognostics.
Quality and aerospace standards: AS9100, NADCAP, ISO, and experience with DFMEA/Control Plans.

Soft Skills

Clear, persuasive written and verbal communication for technical reports, certification packages and customer briefings.
Strong problem solving and root cause analysis capability with structured approaches (5-Why, Ishikawa).
Cross-functional collaboration and stakeholder management across engineering disciplines, suppliers and regulatory bodies.
Leadership and mentorship to grow junior talent and lead multi-disciplinary teams through complex test programs.
Project planning, prioritization and time management to meet program milestones and certification schedules.
Attention to detail with rigorous documentation and configuration control discipline.
Adaptability to changing program priorities and rapid iteration during test and development phases.
Negotiation and supplier management skills to drive quality, cost and delivery improvements.
Presentation skills for executive and customer-facing technical reviews.
Continuous improvement mindset and proactive risk mitigation orientation.

Education & Experience

Educational Background

Minimum Education:

Bachelor of Science (BSc) in Aerospace Engineering, Mechanical Engineering, Propulsion Engineering or closely related field.

Preferred Education:

Master’s (MSc) or PhD in Aerospace Propulsion, Turbomachinery, Thermo-Fluids, Materials Science or equivalent with propulsion-focused research or thesis.

Relevant Fields of Study:

Aerospace / Propulsion Engineering
Mechanical Engineering (Thermodynamics, Fluid Mechanics)
Materials Science & Metallurgy
Applied Mathematics, Controls or Systems Engineering

Experience Requirements

Typical Experience Range: 3–12+ years in gas turbine or turbomachinery engineering, with variation depending on seniority level.

Preferred:

5+ years direct experience in jet engine / gas turbine design, testing and certification for commercial or defense programs.
Demonstrated history of leading engine test campaigns, supporting FAA/EASA certification, and delivering production-ready engine hardware.
Experience in supplier management, NDT inspection programs, and in-service sustainment or MRO operations is strongly preferred.
Familiarity with industry standards (AS9100, NADCAP) and hands-on experience with CFD/FEA tools, CAD/PLM and data analysis workflows.