Key Responsibilities and Required Skills for Jet Propulsion Engineer

🎯 Role Definition

The Jet Propulsion Engineer is responsible for the end-to-end engineering of propulsion systems for rockets, satellites, and in-space vehicles. This role covers design, analysis, test planning, ground and hot-fire test execution, troubleshooting, integration with vehicle systems, and lifecycle support. The ideal candidate brings deep expertise in liquid and/or solid rocket propulsion, chemical and thermal processes, modeling and simulation (CFD/FEA), systems engineering, and hands-on test experience. This position operates at the intersection of propulsion subsystem engineering, vehicle integration, and mission assurance to deliver reliable, high-performance propulsion hardware and software.

📈 Career Progression

Typical Career Path

Entry Point From:

Aerospace Propulsion Engineer I / Junior Propulsion Engineer
Mechanical Engineer with propulsion or fluid dynamics focus
Rocket Engine Test Technician transitioning into engineering

Advancement To:

Senior Jet Propulsion Engineer
Propulsion Team Lead / Lead Propulsion Systems Engineer
Propulsion Systems Architect or Chief Propulsion Engineer

Lateral Moves:

Systems Engineering (Spacecraft or Launch Vehicle)
Thermal / Fluid Systems Engineer
Test & Verification Engineering (Integration and Test)

Core Responsibilities

Primary Functions

Lead the conceptual and detailed design of liquid and/or solid rocket propulsion systems, including combustion chambers, injectors, turbopumps, valves, and pressurization systems, ensuring designs meet thrust, specific impulse, mass, and reliability requirements.
Develop and apply analytical and numerical models (1D performance codes, CFD, FEA) to predict engine performance, combustion stability, heat transfer, structural response, and transient behaviors across mission profiles.
Define propulsion system architectures, interfaces, and requirements in collaboration with vehicle systems engineering; write, manage, and trace requirements from system level down to component level using formal requirements tools.
Produce detailed CAD models, manufacturing drawings, and tolerance specifications for propulsion hardware; work with manufacturing and supply chain teams to ensure producibility and cost control.
Plan, develop, and execute ground test programs including cold flow, ignition, hot-fire, vacuum, and altitude simulator tests; generate detailed test procedures, instrumentation plans, and test safety documentation.
Lead hot-fire test campaigns: coordinate test stands, propellant handling, instrumentation, data acquisition, and post-test analysis to validate performance and qualify hardware for flight.
Perform propulsion system integration and acceptance activities, including vehicle integration planning, interface verification, launch site support, and in-line acceptance testing.
Conduct failure modes, effects, and criticality analyses (FMEA/FMECA), fault trees, and risk assessments to identify, mitigate, and document propulsion risks across development and production.
Develop and validate ignition and pressurization strategies, propellant feed systems, and thermal control approaches to achieve mission-specific boil-off and pressurization margins.
Characterize propellant chemistries, compatibility, and handling procedures; define safe storage, ground operations, and handling plans for hypergolic, cryogenic, storable, and composite propellants.
Implement combustion stability mitigation strategies (e.g., baffles, acoustics damping, injector patterning) and lead stability testing with data-driven corrective designs.
Support additive manufacturing and advanced materials selection for propulsion components; validate post-process heat treatments and nondestructive evaluation (NDE) techniques to meet mechanical and thermal performance.
Work cross-functionally with avionics, structures, thermal, guidance & navigation, and vehicle systems teams to ensure propulsion system requirements are met and integrated into mission timelines.
Create and review technical deliverables: trade studies, design reviews (PDR/CDR), qualification plans, flight acceptance procedures, and certification documentation for propulsion hardware.
Develop simulation toolchains and automated analysis scripts (MATLAB, Python, C++) for performance prediction, regression testing, and sensitivity analyses to accelerate design iterations.
Manage supplier relationships for specialized components (turbomachinery, valves, seals, coatings); qualify vendors, review manufacturing processes, and perform incoming inspection and acceptance test planning.
Perform thermal and structural design of thrust chambers, nozzles, and plumbing; specify cooling strategies (regenerative, film, ablative, radiative) and validate via thermal cycling and testing.
Lead anomaly resolution and root cause investigations for propulsion failures or degraded performance; produce corrective action plans and incorporate lessons learned into future designs.
Prepare and present technical summaries, test results, and risk/status briefings to program leadership, customers, regulatory agencies, and cross-functional stakeholders.
Ensure compliance with safety, environmental, and regulatory requirements for propulsion development and ground operations, including hazardous materials handling and launch site regulations.
Drive continuous improvement in propulsion processes, including design-for-manufacture (DFM), reliability growth plans, and maintainability assessments; champion technical innovation and efficiency.
Mentor junior propulsion engineers and technicians, establishing best practices for engineering analyses, test execution, and documentation to build team capability and institutional knowledge.

Secondary Functions

Support ad-hoc data requests and exploratory data analysis.
Contribute to the organization's data strategy and roadmap.
Collaborate with business units to translate data needs into engineering requirements.
Participate in sprint planning and agile ceremonies within the data engineering team.
Assist with proposal development, cost/schedule estimates, and technical risk assessments for new propulsion projects.
Provide on-call support for launch campaigns and critical test operations including remote monitoring and rapid decision support.

Required Skills & Competencies

Hard Skills (Technical)

Rocket propulsion system design (liquid bipropellant, cryogenic, hypergolic, or solid rocket motors)
Thermodynamics, combustion, and propellant chemistry knowledge for performance and safety assessments
Computational Fluid Dynamics (CFD) for nozzle and plume analysis; experienced with toolsets such as ANSYS Fluent, OpenFOAM, or equivalent
Finite Element Analysis (FEA) for thermal and structural modeling (ANSYS Mechanical, NASTRAN, Abaqus)
1D performance and system simulation tools (ROCCID, RocketSIM, CEA, Python-based codes)
Heat transfer, cooling strategies (regenerative cooling, film cooling, ablatives) and thermal analysis
Hot-fire and vacuum test planning, instrumentation (pressure transducers, thermocouples, strain gauges), and data acquisition systems
CAD proficiency (SolidWorks, CATIA, NX) and GD&T for mechanical drawings and manufacturing interfaces
Model-Based Systems Engineering (MBSE) and requirements management tools (DOORS, Polarion, Jama)
Programming and scripting for analysis automation and data processing (Python, MATLAB/Simulink, C/C++)
Experience with turbomachinery and pump/turbine design and analysis (for pump-fed liquid engines)
Additive manufacturing processes and qualification methods for propulsion components
Safety engineering: explosive/pyrotechnic systems, hazardous material handling, and ground support equipment protocols
Test stand design, plumbing, and propellant feed system design, including valves, regulators, and pressure control

Soft Skills

Clear technical writing and documentation skills for requirements, test plans, reports, and certification artifacts
Strong verbal presentation and stakeholder communication skills for reporting to program leadership and customers
Proven problem solving and root-cause analysis capability under time pressure and during test anomalies
Collaborative teamwork mindset across multidisciplinary engineering and operations teams
Leadership and mentorship: ability to train junior staff and lead small cross-functional teams
Time management and prioritization to meet schedule-driven milestones in high-stakes flight programs
Attention to detail and quality mindset to ensure compliance with safety and reliability standards
Adaptability and continuous learning attitude toward new propulsion technologies and manufacturing methods

Education & Experience

Educational Background

Minimum Education:

Bachelor of Science (B.S.) in Aerospace Engineering, Mechanical Engineering, Chemical Engineering, or equivalent with a technical emphasis in propulsion, fluids, or combustion.

Preferred Education:

Master of Science (M.S.) or Ph.D. in Aerospace Engineering, Propulsion, Combustion, or related field with thesis or project work in rocket engines, turbomachinery, or high-temperature fluids.

Relevant Fields of Study:

Aerospace Engineering
Mechanical Engineering (with fluid/thermal emphasis)
Chemical Engineering (propellant chemistry, combustion)
Materials Science (high-temperature materials, coatings)
Systems Engineering / Controls (for integrated propulsion and avionics interaction)

Experience Requirements

Typical Experience Range: 3–12+ years depending on seniority (e.g., 3–5 years for mid-level, 7–12+ for senior/lead roles)

Preferred:

Demonstrated hands-on experience with engine/component design, hot-fire test execution, and vehicle integration on flight or qualification programs
Prior work on flight propulsion systems (orbital launch vehicles, upper stages, in-space propulsion) or equivalent large ground-test systems
Experience with regulatory and launch site operations, including hazardous propellant handling procedures and safety approvals