BluJ Aerospace Private Limited
Website:
blujaero.com
Job details:
Lead Engineer – Systems Integration (Avionics and Propulsion)
Team: Avionics & Propulsion | Location: Adibatla, Hyderabad
Employment Type: Full-time | Experience: 5+ years
Job Description:
We are looking for a hands-on integration lead to own the aircraft as an electrical system — the engineer who makes in-house boards and bought-in subsystems behave as one aircraft. Your scope covers battery packs from 60 V to 400 V with in-house and third-party battery management, datalink radios and radar altimeters from external suppliers, CAN-based servo actuators, open-source and commercial flight controllers, power distribution boards with active pre-charge and buck converters, in-house and open-source-derived motor controllers, and the connectors, harnesses and test rigs that tie them together.
You will lead a small integration team while staying technically hands-on: writing the interface definitions, drawing the harnesses, building the hardware-in-the-loop bench, and signing off that a build is safe to power on. Roughly half your week is your own bench and documentation work; the rest is planning and unblocking the team. Integration is where subsystem assumptions meet, and this role exists to find those conflicts on a bench rather than in flight. The interface documents you write and the test rigs you build will be how BluJ integrates aircraft for years.
About BluJ:
BluJ Aero is formed with the vision of making Aviation 'Simpler & Sustainable'. We are working on cutting-edge Vertical Take-off and Landing (VTOL) technologies and aim to cut down travel time for cargo and humans significantly. We are looking for passionate and ambitious people to form our core foundation team.
Key Responsibilities:
Architecture and interfaces
- Own the aircraft-level electrical and data architecture — what connects to what, over which bus, at what voltage, and how it behaves when a link or a supply is lost — and keep it as a single documented source of truth.
- Own an interface control document for every subsystem — bus message sets and addressing, telemetry and command parameters, power rails, signal levels, timing and startup — and own bus design and loading across mixed CAN and vendor-proprietary protocols: segmentation, termination, bit rates, load budgets, redundancy on flight-critical buses.
- Own the power tree from pack to load across th 60 V to 400 V variants: battery management integration and fault paths, contactor and active pre-charge sequencing, buck converter rails, inrush, isolation monitoring and protection coordination.
- Own the aircraft-level EMC picture keeping noise out of the avionics and the flight controller.
Harness, connectors and installation
- Own harness design and its documentation: wiring diagrams, harness drawings, pin lists, wire sizing and derating, connector and backshell selection, labelling and HV/LV/signal separation.
- Own the as-built configuration — harness revisions under change control and traceability from diagram to the aircraft on the floor — and work with structures on routing, clamping and maintenance access.
Suppliers and subsystem qualification
- Own the technical relationship with subsystem suppliers: specification, evaluation, firmware version control, issue escalation, and the trade studies behind each buy-versus-build decision.
- Define incoming acceptance tests for every bought-in part, and lock the qualified hardware and firmware configuration.
Test, verification and delivery
- Own subsystem and integration test plans end to end — bench, hardware-in-the-loop, iron bird, power-on checkout, ground and flight test support — with defined pass/fail criteria.
- Build and own the hardware-in-the-loop rig: flight controller in the loop with simulated sensors, actuators, battery and loads, plus bus traffic and fault injection, logging and repeatable regression runs.
- Own failure-mode testing across subsystem boundaries — pre-charge and contactor faults, battery management trips, bus dropout, actuator loss, link loss and failsafes — verifying that the aircraft degrades the way the architecture claims.
- Own the integration schedule and issue log with root-cause discipline rather than closing issues once the symptom disappears, and hold the decision on whether a build is ready to fly.
- Lead and mentor a small integration team, working across hardware, firmware, flight controls, structures, flight test and supply chain.
Must-Have Qualifications:
- Bachelor's or master's degree in Electrical, Electronics, Aerospace, Mechatronics or a related engineering discipline.
- 6+ years in electrical or systems integration, including 2+ years leading engineers or programs.
- Demonstrated ownership of vehicle- or aircraft-level electrical integration — taking a set of subsystems from parts to a functioning, instrumented and tested vehicle.
- Deep hands-on CAN experience, including higher-layer protocols and autopilot command and telemetry links: you can read traces on a bus analyser and diagnose arbitration, loading and addressing problems.
- Hands-on with open-source or commercial flight controllers — parameters, logs, failsafes, actuator setup.
- High-voltage battery integration: multi-voltage packs, in-house or third-party battery management, contactor and pre-charge sequencing, isolation monitoring and disciplined HV safety.
- Harness and connector design for airborne or automotive use — wiring diagrams, wire sizing and derating, connector selection for vibration and environment, and EMC-aware routing.
- Built or owned a hardware-in-the-loop or bench test rig, and written test plans others could execute, with the discipline to keep interface and configuration records current.
- Hands-on bench competence: you are comfortable with a scope, a logic analyser and a bus analyser, and patient with intermittent faults that live between two subsystems.
Nice to Have:
- Experience on eVTOL, UAV or hybrid-electric aircraft programs; datalink or radar altimeter integration — link budgets, antenna placement and RF coexistence with switching power stages.
- Working knowledge of DO-160, ARP4754A or DGCA/EASA SC-VTOL requirements; Python for test automation and flight-log analysis; Altium or similar for harness work.
- We appreciate people who lead by example, and who believe no task is too small to be done.
What Success Looks Like in the First Year:
By month 3 the current aircraft has a complete, trusted set of interface and power-tree documents and a prioritised list of integration risks. By month 6 the hardware-in-the-loop rig runs a repeatable checkout suite and the harness set is under change control. By month 12 an aircraft can be built, powered on and checked out from documentation alone, every bought-in subsystem has an acceptance test, and integration is no longer the reason a first flight timeline slips.
What We Offer
- Ownership of the interfaces that decide whether a clean-sheet aircraft flies.
- A collaborative and innovative work environment where engineering decisions are made by the people closest to the hardware.
- Opportunities for professional growth and development.
- A culture that values diversity and inclusion.
The role combines desk work, lab and test-bench time, and on-site testing in various weather conditions; some travel is required for field testing and for supplier work.
We thank all applicants for their interest, but only those selected for an interview will be contacted. BluJ Aero is an equal opportunity employer and encourages applicants from all backgrounds to apply.
Click on Apply to know more.