Propeller Design Engineer

About Sarla Aviation:Sarla Aviation is at the forefront of revolutionizing urban air mobility with its cutting-edge eVTOL (electric Vertical Take-off and Landing) aircraft featuring innovative tilt-rotor technology. Sarla Aviation, a pioneer in the development of sustainable, efficient, and safe air transportation systems, is dedicated to influencing the future of aviation. We are seeking a skilled and driven Propeller Design Engineer to join our expanding team and contribute to the success of our eVTOL program.Role Overview:The Propeller Design Engineer will be responsible for the end-to-end design, analysis, optimization, and validation of propeller systems for Sarla Aviation’s eVTOL aircraft. This includes fixed and tilting propellers with variable pitch mechanisms operating across hover, transition, and forward flight regimes. The role demands deep technical expertise in aerodynamics, aeroelasticity, structural design, and mechanical integration, with strong ownership from early concept definition through flight test support and certification readiness.Key Responsibilities:Own the aerodynamic and mechanical design of fixed and tilt propellers with variable pitch systems for multi-regime eVTOL operation (hover, transition, and cruise). Define propeller performance requirements including thrust, efficiency, power loading, acoustic limits, and operational margins across the full flight envelope. Develop and optimize blade geometry (airfoils, twist, chord, sweep, tip treatments) for maximum aerodynamic efficiency, stall margin, and noise reduction. Establish and maintain high-fidelity aero-structural and aeroelastic analysis toolchains, including BEM, CFD, FEA, and coupled simulations. Perform unsteady aerodynamic and aeroelastic analyses to assess blade loads, flutter margins, vibratory stresses, and dynamic stability. Design and validate variable pitch mechanisms, including kinematics, actuation concepts, load paths, backlash control, response time, and fail-safe behaviour. Define structural concepts and composite layups for blades and hubs, balancing strength, stiffness, fatigue life, damage tolerance, and mass targets. Collaborate closely with propulsion, motor, inverter, flight controls, EWIS, and systems teams to ensure seamless propeller-motor-controller integration. Define propeller-related loads, interface requirements, and operating limits for aircraft-level loads, dynamics, and flight control models. Plan, execute, and analyze wind tunnel, whirl-tower, ground, and flight tests to validate aerodynamic, structural, acoustic, and control performance. Lead root-cause investigations for performance shortfalls, vibration issues, noise exceedances, or durability concerns during testing. Support certification activities by generating compliance artifacts aligned with FAR/EASA and emerging eVTOL propulsion and propeller requirements. Drive internal R&D initiatives focused on advanced propeller concepts, low-noise architectures, new materials, and next-generation pitch actuation systems.Required Qualifications:Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or a closely related discipline. 6+ years of hands-on experience in propeller, rotor, or propulsion system design for aerospace applications (eVTOL, rotorcraft, UAVs, or turboprop). Strong foundation in propeller aerodynamics, rotor theory, aeroelasticity, and unsteady flow phenomena. Proficiency in CAD tools such as Siemens NX or SolidWorks for blade, hub, and pitch mechanism design. Practical experience with CFD and FEA tools for aerodynamic, structural, and coupled aero-structural analysis. Demonstrated experience designing or analysing variable pitch propellers or rotor systems. Solid understanding of vibration, fatigue, and dynamic loading in rotating machinery. Ability to translate aircraft-level performance and control requirements into propeller-level design targets. Strong technical communication skills, with the ability to present analyses and design decisions to internal and external stakeholders. Familiarity with aerospace regulatory frameworks (FAR, EASA) and early-stage eVTOL certification considerations.Preferred Qualifications:Direct experience with tilt-rotor or tilt-wing aircraft architectures. Hands-on experience with composite blade manufacturing processes and supplier coordination. Exposure to electric propulsion systems, including motor-propeller matching and efficiency optimization. Experience with acoustic modelling, psychoacoustics, and low-noise propeller design techniques. Background in experimental testing, including wind tunnel, whirl-tower, or flight test instrumentation and data reduction. Prior involvement in certification or compliance-driven development programs.Why Join Us?:Be a part of a world-class team in an environment where your work directly contributes to shaping the future of urban air mobility. Thrive in our culture of diversity, inclusion, and innovation, where your unique perspectives and ideas are valued. Enjoy a competitive compensation package, with opportunities for growth and development in a rapidly evolving industry.Sarla Aviation is dedicated to creating a diverse and inclusive workspace, championing equality and empowering every individual. We believe that our strength lies in our differences, not just our similarities. Therefore, we warmly welcome applications from all qualified candidates, regardless of their ethnicity, gender, disability, religion, sexual orientation, or age. Join us at Sarla Aviation, where your unique background and perspective are not just welcomed—they are celebrated.

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