Contract Flight Test Engineer Jobs in Exton, PA (NOW HIRING)

Description

The Systems Engineer is responsible for the technical planning, system-level design, environmental qualification, integration, verification, and lifecycle management of complex aerospace systems. This role ensures that customer requirements, environmental performance, regulatory standards, and organizational objectives are translated into reliable, high-performing products. The Systems Engineer serves as the technical bridge between hardware, software, manufacturing, test, quality, and program management teams.

Lead systems engineering activities across the full product lifecycle (concept, development, environmental qualification, verification, production, and sustainment).

Develop and manage system requirements, specifications, and interface control documents (ICDs).

Perform requirements decomposition, traceability, and verification planning, including environmental and stress qualification requirements.

Conduct system architecture development, trade studies, and risk assessments.

Define and oversee environmental test strategies including temperature, vibration, shock, humidity, altitude, EMI/EMC, lightning, and fluids susceptibility.

Support and witness environmental qualification testing to RTCA DO-160, MIL-STD-810, MIL-STD-461, and other applicable standards.

Analyze environmental test data, identify failures, lead root cause analysis, and drive corrective actions.

Support system integration, test planning, verification, and validation (V&V).

Ensure compliance with aerospace standards such as ARP4754A, DO-178, DO-254, AS9100, MIL-STD, and related regulations.

Lead failure modes and effects analysis (FMEA), fault tree analysis (FTA), and reliability assessments incorporating environmental stress factors.

Coordinate with cross-functional teams including mechanical, electrical, software, manufacturing, test, quality, and supply chain.

Support customer technical reviews and design reviews (SRR, PDR, CDR, TRR) with emphasis on qualification and certification readiness.

Manage system-level risks, configuration control, and change management.

Support transition from development to production and fielded system support, including environmental re-qualification as needed.

Requirements

Bachelor's degree in systems engineering, Aerospace Engineering, Electrical Engineering, Mechanical Engineering, or related field.

5+ years of experience in systems engineering within the aerospace or defense industry.

Direct experience with environmental qualification testing to DO-160, MIL-STD-810, MIL-STD-461, or equivalent military/commercial standards.

Strong understanding of the systems engineering V-model and lifecycle processes.

Experience with requirements management tools (e.g., DOORS, Jama, Polarion).

Knowledge of aerospace certification and regulatory frameworks.

Proven ability to perform system-level trade studies and technical decision-making.

Strong communication, documentation, and cross-functional leadership skills.

Master's degree in systems or aerospace engineering.

Experience with avionics, flight control systems, propulsion, UAS, or space systems.

Hands-on experience planning or executing environmental tests in certified test labs.

Familiarity with model-based systems engineering (MBSE) using tools such as SysML, Cameo, or Rhapsody.

Experience supporting certification or qualification activities with FAA, DoD, NASA, or commercial aerospace organizations.

Systems Thinking

Environmental & Qualification Testing

Technical Leadership

Risk Management

Requirements Analysis

Interface Management

Test & Verification Planning

Cross-Functional Collaboration

Office, laboratory, and environmental test facility environments.

Occasional exposure to vibration tables, thermal chambers, and flight-line or production floor environments.

Light-Exerting up to 20lbs/9kg of force frequently, and/or negligible amount of force frequently to move objects.

Competitive salary based on experience

Performance-based bonus

Comprehensive medical, dental, and vision insurance

401(k) with company match

Paid time off and holidays

U.S. PERSON REQUIREMENTS

Due to compliance with U.S. export control laws and regulations, candidate must be a U.S. citizen, U.S. permanent resident, or have asylum or refugee status in the U.S.

Equal Opportunity Employer/Veterans/Disabled.  

IA is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, or protected veteran status and will not be discriminated against on the basis of disability.