Staff Test Engineer / Test Team Lead

Staff Test Engineer/Test Team Lead 

Job Summary:  

ESAero is seeking an experienced Staff Test Engineer/Test Team Lead to oversee and execute all aspects of our test operations. This critical role is responsible for leading a multidisciplinary test team, coordinating test planning and execution, and ensuring all activities are carried out safely, efficiently, and in accordance with applicable regulations and program goals. The ideal candidate will bring strong technical expertise, leadership experience, and a background in military or military contract testing.   

Key Responsibilities:  

• Lead the test team in planning, coordinating, and executing test campaigns from initial test planning through post-test analysis and reporting.  

• Resource manager for a small team of test engineers. Tasks include timecard approvals, PTO requests, team loading, and gather concerns and improvements ideas. 

• Propose, develop, and maintain processes, procedures, and tooling that improve quality, efficiency, and cleanliness in regard to testing, test development, or test equipment. 

• Safety review for hazardous testing.  

• Develop and manage detailed test plans, procedures, and schedules to meet program objectives.  

• Ensure all tests comply with applicable safety regulations, company policies, and government standards (e.g., OSHA, DoD).  

• Coordinate with engineering, facilities, maintenance, program management, and other stakeholders to ensure test readiness and resource availability.  

• Serve as the primary point of contact for test activities, internally and externally.  

• Identify risks and develop mitigation strategies to maintain test program integrity and safety.  

• Review and approve test documentation, including test cards, data collection plans, and safety assessments.  

• Analyze test data in collaboration with engineers and provide feedback to improve article performance.  

• Assist with troubleshooting and root cause investigation of issues observed during testing.  

• Develop expert-level knowledge of the component, systems, and aircraft under test.  

• Develop test equipment manuals and support documentation necessary for safe testing in accordance with established operating procedures.  

• Support training and mentoring of junior test personnel.  

• Continuously assess and improve the test team’s capabilities, processes, and tools to enhance performance, safety, and efficiency.  

• Other duties as assigned or required.  

Required Qualifications:  

• Bachelor’s degree in engineering.  

• 10 years of experience in test operations, with a demonstrated ability to lead teams and manage complex flight test campaigns.  

• 2 years in a management role. 

• Experience in process improvement 

• Excellent understanding of test planning, execution, and data analysis.  

• Proven experience with test safety protocols and government regulations applicable to testing.  

• Familiarity with electronics testing.  

• Fundamental understanding of other disciplines including stress, dynamics, thermal analysis, production, electronics, power electronics, systems engineering, etc.  

• Experience with data collection and reduction software (LabView, MatLab, or similar) 

• Excellent communication and organizational skills.  

• Proven leadership capabilities in a fast-paced, high-stakes environment.  

• Willing to relocate to San Luis Obispo, CA 

• Ability to work on DoD projects.  

Preferred Qualifications:  

• Master’s degree in Aerospace or Electrical or equivalent. 

• 5 years in a management role. 

• Experience with power distribution systems theory, design, test, or analysis. 

• Experience with electric motor and controller/inverter theory, design, test, or analysis. 

• Experience in engineering testing safety methods and standards. 

• Able to work with high voltage (>500V)  

• Experience with digital communication protocols such as SPI, Ethernet, and CAN bus.  

• Familiarity with Military standards relating to the design of high-power/voltage electrical system and electromagnetic compatibility for aircraft. 

• Experience in UAS design. 

• Experience with design and testing for moderate rate manufacturing. 

• Hands-on experience working with machine shops, integrating prototype designs, and conducting validation tests. 

• Experience with Risk Management. 

• Familiarity with Military standards relating to the mechanical design of aircraft. 

• Experience with supplier management and procurement (such as SOWs, RFPs, and/or vendor management). 

• Technical Lead Experience 

Work Environment and Travel:  

• This role requires some hands-on work at test sites and may involve travel to various test locations.  

• Must be able to work in both office and field environments  

Comprehensive Benefits & Perks: 

• Health & Wellness: Choose from three health, dental, and vision plans - including a 100% employer-paid option covering both employees and their families. 

• Paid Time Off: Enjoy 120 hours of PTO, 80 hours accrued plus an additional 40 hours of holiday break pay in addition to Christmas Eve, Christmas Day, and New Year’s Day off. 

• Life Insurance: $25,000 employer-paid life insurance policy, with the option to purchase additional coverage for employees and their families. 

• Supplemental Coverage: Access optional benefits such as Critical Illness, Hospital Indemnity, Accident Insurance, and Critical Illness with Skin Cancer coverage. 

• Health Savings Account (HSA): Take advantage of a tax-advantaged HSA to manage medical expenses. 

• Retirement Savings: 401(k) with a company match to support your financial future. 

• Paid Holidays: Enjoy 9 paid holidays throughout the year. 

• Work Environment: A casual dress code, complimentary snacks, and a welcoming company culture. 

• Ideal Location: Work in an area that offers an outstanding quality of life - a perfect place to live, work, and play! 

Company Overview 

Empirical Systems Aerospace, Inc (ESAero) is a leader in aerospace engineering, product development, and manufacturing, dedicated to delivering high-quality, innovative, and cost-effective solutions to the industry. We specialize in cutting-edge system design, rapid product development, precision manufacturing, comprehensive testing, and technology demonstrations to support the evolving needs of the aerospace community. Committed to excellence, on-time delivery, and continuous growth, we invest in infrastructure to expand our manufacturing and aftermarket capabilities while maintaining the highest standards of engineering services. 

At ESAero, we don’t just build products, we engineer solutions that propel  

the aerospace industry forward. 

**This position is fully on-site at ESAero in San Luis Obispo, CA** 

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ESAero is an equal opportunity employer.  
E-Verify participation required for employment.  
Must present proof of authorization to work in the United States.     
Must be able to pass background check.    
Pay Range: $140-175k Salary Exempt (DOE) 

Salary : $140,000 - $175,000