Key Responsibilities and Required Skills for Jet Testing Engineer

🎯 Role Definition

The Jet Testing Engineer is a specialized propulsion test engineer responsible for planning, executing, analyzing, and reporting on jet engine and turbomachinery tests in ground test cells and flight test programs. This role combines deep technical knowledge of gas turbine engines (turbofan, turbojet, turboprop), instrumentation and data acquisition systems, test safety and certification processes (FAA/EASA), and applied engineering problem-solving to validate performance, reliability, emissions, vibration and durability across development and production phases.

Core focus areas: engine performance testing, instrumentation & calibration, test cell operations, safety & compliance, root-cause analysis, test automation, and clear technical reporting for certification and development stakeholders.

Keywords: Jet Testing Engineer, aircraft engine testing, propulsion test engineer, turbofan test, test cell operations, data acquisition, FAA certification, turbine engine performance, vibration testing, emissions testing.

📈 Career Progression

Typical Career Path

Entry Point From:

Propulsion Test Technician or Engine Test Operator transitioning to engineering responsibilities
Mechanical or Aerospace Design Engineer with exposure to engine design and test programs
Graduate Engineer (Aerospace/Mechanical) with internships in test laboratories or propulsion groups

Advancement To:

Senior Jet Test Engineer / Lead Propulsion Test Engineer
Test Program Manager or Test Cell Manager
Propulsion Systems Validation Lead or Certification Lead
Principal Engineer — Engine Performance & Durability

Lateral Moves:

Flight Test Engineer (with flight test instrumentation experience)
Reliability & Maintainability Engineer (engine health monitoring)
Systems Integration Engineer for engine controls (FADEC/test integration)

Core Responsibilities

Primary Functions

Plan, develop, and maintain detailed test plans and test procedures for turbofan, turbojet, and auxiliary power unit (APU) test campaigns, ensuring alignment with program objectives, technical specifications, and certification requirements.
Design, specify and coordinate installation of instrumentation packages (pressure transducers, thermocouples, strain gauges, accelerometers, flowmeters, gas analyzers) for engine hot-section, fuel, lubrication, and bleed systems to capture high-fidelity performance and health data.
Configure, validate, and maintain data acquisition and real-time test systems (DAQ hardware, data logger configuration, sampling rates, channel mapping), ensuring synchronized measurement across analog, digital, CANbus and ARINC interfaces.
Calibrate sensors and transducers, oversee calibration traceability, and maintain calibration records to ensure measurement accuracy for performance, emissions, and vibration testing.
Execute ground engine tests in test cells and dynamometer stands — perform engine start, stability checks, steady-state and transient runs, thrust measurement, and instrumentation verification while monitoring engine health and safety systems.
Monitor real-time engine parameters during runs (temperatures, pressures, rotational speed, fuel flow, vibration, torque) and make live decisions to protect hardware, including implementing defined abort criteria and emergency shutdowns (ESDs) where necessary.
Analyze large test datasets using signal processing and statistical techniques to extract performance metrics (specific fuel consumption, thrust, efficiency), identify trends, and quantify uncertainty for engineering review and certification artifacts.
Lead root-cause investigations for anomalies observed during testing — perform correlation of sensor data, video, and log files; run post-test simulations; collaborate with design teams to propose corrective actions and retest plans.
Prepare clear, concise technical test reports, anomaly reports, and formal test summaries for internal stakeholders, customers, and certification authorities, including detailed plots, derived parameters, and test acceptance criteria.
Develop and maintain safety plans, risk assessments, and test cell procedures including hazard analyses, lockout/tagout, hotwork permits, and explosive/flammable material controls, ensuring compliance with company safety standards and FAA/EASA guidance.
Coordinate cross-functional test activities with propulsion design, controls (FADEC), flight test, structures, materials, and manufacturing teams to ensure test objectives, rigging requirements, and timelines are met.
Implement and maintain test automation scripts (LabVIEW, Python, MATLAB/Simulink) to streamline test execution, reduce human error, and ensure reproducible test sequences and data collection.
Manage test cell equipment and facilities: oversee engine stands, thrust measurement systems, gearbox rigs, fuel conditioning systems, ventilation/exhaust systems and cooling systems to meet test demands and environmental controls.
Plan and execute endurance and durability testing campaigns (hours-on-wing simulation, thermal cycling, vibration endurance) to validate component life, wear characteristics, and maintenance intervals.
Perform emissions testing and analysis (NOx, CO, CO2, unburned hydrocarbons, particulates) to support environmental compliance and certification targets using gas analyzers and standardized test cycles.
Coordinate with suppliers and external test labs for specialized testing (material characterization, NDT inspections, hot-fire component testing) and ensure data integrity, configuration control and timely delivery.
Control configuration management for test articles, instrumentation harnesses and software versions — document test article status, modifications, and non-conformances to maintain traceability for certification evidence.
Support preparation of certification packages by supplying validated test data, witness plans, and objective evidence to regulatory authorities (FAA, EASA) during engine type certification or supplemental type certification activities.
Mentor and train junior test engineers and technicians in safe test practices, instrumentation techniques, data analysis methods and company test standards to build team capability and continuity.
Maintain test program schedules, resource allocation, and cost tracking for assigned test campaigns — identify critical path items and recommend mitigation to meet program milestones.
Conduct vibration and structural testing (engine mounts, accessory gearbox, fan blade instrumentation), including modal surveys and operational deflection shape analysis to detect resonant behavior and ensure structural integrity.

Secondary Functions

Support ad-hoc engineering data requests and provide exploratory analysis for design and flight test teams using test data lakes and analysis tools.
Contribute to continuous improvement of test processes, instrumentation standards, and test automation frameworks to reduce test cycle time and increase data quality.
Work with procurement and logistics to source specialized sensors, data acquisition equipment, and test fixtures; validate supplier technical deliverables against test requirements.
Participate in design reviews to provide testability feedback and recommend sensor placement, access ports, and hardware interfaces for future engine builds.
Assist quality assurance with non-conformance investigations and corrective action plans related to test hardware, instrumentation failures, or measurement discrepancies.
Collaborate with environmental health & safety (EHS) to update emergency procedures, training, and personal protective equipment (PPE) requirements specific to propulsion test operations.
Provide subject matter expertise for bid and proposal phases, estimating test scope, schedule, and technical risk for customer engine test contracts.
Maintain test documentation repositories and ensure archival of raw and processed test data in accordance with data retention policies and certification evidence requirements.

Required Skills & Competencies

Hard Skills (Technical)

Deep understanding of gas turbine engine thermodynamics, propulsion system performance, compressor and turbine maps, and turbine engine control logic (FADEC).
Experienced in planning and executing ground and flight engine tests, including steady-state, transient, surge/stall characterization, idle-to-full-power runs and shut-down procedures.
Proficient with instrumentation design and sensor selection: temperature (thermocouples/RTDs), pressure transducers, strain gauges, piezo accelerometers, optical RPM sensors and flow measurement.
Hands-on experience with data acquisition systems (NI LabVIEW/DAQmx, MDT, DEWESOFT, CSC, or equivalent) and real-time data logging architectures.
Strong data analysis skills using MATLAB, Python (numpy, pandas, scipy), Excel, or dedicated signal-processing tools for filtering, FFT, spectral analysis, and uncertainty quantification.
Familiarity with test automation scripting and control systems (LabVIEW, Python scripting, PLCs, real-time control, and SCADA interfaces).
Knowledge of emissions measurement techniques and analyzers (NDIR, chemiluminescence), and protocols for environmental compliance testing.
Experience performing vibration analysis, modal testing, order tracking, and using tools like ME’scope, LMS, or nCode for fatigue predictions.
Working knowledge of certification processes and regulatory standards (FAA/EASA, AS9100, ISO 9001) for propulsion systems and test evidence requirements.
Competent with mechanical systems, rigging, hydraulic/pneumatic systems, fuel delivery systems and test cell utilities management.
Proficient in CAD basics (SolidWorks, CATIA) to interpret test fixtures and help specify mounting and routing for instrumentation harnesses.
Strong troubleshooting skills in both hardware and software domains to quickly isolate sensor failures, wiring faults, and DAQ issues.
Experience with configuration management tools, test documentation best practices, and test procedure generation tools.
Familiarity with non-destructive inspection (NDT) techniques and hot-section materials for post-test inspections.
Knowledge of safety-critical systems, hazard analysis, and ability to develop safe operating procedures for high-energy propulsion tests.

Soft Skills

Clear and effective written and verbal communication for technical reporting, cross-discipline coordination, and regulatory interactions.
Strong problem-solving and analytical mindset with attention to measurement uncertainty and data integrity.
Collaborative team player who can coordinate multi-disciplinary teams across propulsion, structures, controls, and flight test.
High level of personal responsibility and safety consciousness — enforces and follows test cell safety protocols.
Time management and organizational skills for simultaneous management of multiple test activities and deliverables.
Adaptability and composure under pressure during live engine test operations and anomaly conditions.
Mentoring and leadership capability to coach junior engineers and technicians.
Customer-facing skills for interactions with external customers, suppliers, and regulatory representatives.
Detail-oriented documentation skills to produce traceable test artifacts suitable for certification and audits.
Project-oriented mindset, including risk identification, mitigation planning, and schedule-driven execution.

Education & Experience

Educational Background

Minimum Education:

Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Propulsion, or a closely related engineering discipline.

Preferred Education:

Master’s degree in Aerospace Propulsion, Mechanical Engineering, or Combustion & Turbomachinery.
Additional certifications in test engineering, vibration analysis, or quality systems (AS9100, Six Sigma) are advantageous.

Relevant Fields of Study:

Aerospace Engineering
Mechanical Engineering (with emphasis on thermodynamics/fluids)
Propulsion / Turbomachinery
Instrumentation and Control Systems

Experience Requirements

Typical Experience Range:

3–10 years of hands-on experience in engine test programs, engine performance analysis, or propulsion test facilities. Entry-level roles may accept 1–3 years with strong internship/test-stand exposure.

Preferred:

5+ years of direct jet/turbine engine testing experience (turbofan, turbojet, APU), proven track record of leading test campaigns, and participation in certification efforts.
Experience in both ground test cell operations and flight test support is highly valued.