Senior Systems Modeling Engineer

Location: South San Francisco, California, USA

Department: Hardware

About You and The Role 

You will be part of Zipline's Systems Modeling Team, which develops physics-based models used to architect, optimize, and validate Zipline's aircraft hardware and operational systems. Electric propulsion performance directly impacts aircraft efficiency, mission capability, thermal management, operating cost, and fleet reliability.

You will lead the development of Zipline's electric propulsion modeling capability, spanning motors, inverters, gearboxes, and propellers—from component physics through integrated aircraft and fleet-level behavior. Your models will guide propulsion hardware design, operating limits, thermal management, and control strategies, enabling better engineering decisions throughout the product lifecycle.

This is an engineering ownership role—not a simulation support role. You will drive the complete modeling lifecycle, from first-principles model development and parameter identification through experimental validation, deployment into engineering workflows, and continuous improvement using laboratory testing and production flight data.

What You'll Do

• Develop and validate physics-based models of electric propulsion systems across multiple levels of fidelity, supporting aircraft simulation, hardware design, controls development, and fleet operations.
• Design and lead characterization campaigns for parameter identification and model validation, defining test requirements, instrumentation, and procedures for dynamometer, thrust stand, wind tunnel, and thermal testing.
• Drive engineering and operational decisions through quantitative analysis and trade studies, influencing propulsion architecture, operating limits, thermal management, control strategies, aircraft performance, and fleet reliability.
• Build and own clean, modular, object-oriented modeling frameworks and engineering tools that are maintainable, reusable, and scalable across aircraft programs.
• Continuously improve model fidelity by comparing predictions against laboratory testing and production flight data, identifying model deficiencies, and deploying validated improvements that increase predictive accuracy across the fleet.
• Partner closely with electrical, mechanical, thermal, controls, flight test, manufacturing, and fleet operations teams to translate modeling insights into better products and engineering decisions. 

What You'll Bring

• 8+ years of industry experience developing and validating physics-based models for electric powertrains, aerospace systems, electric vehicles, robotics, or other complex electro-mechanical systems.
• Demonstrated ability to design experimental characterization campaigns for parameter identification and model validation, including defining test plans, instrumentation, and measurement requirements.
• Track record of using quantitative analysis and modeling to drive engineering decisions, including design trade studies, operating limits, performance optimization, or system architecture decisions.
• Proficiency in MATLAB, Python, Julia, Rust, or similar languages, with experience developing clean, modular, object-oriented engineering code and reusable modeling frameworks.
• Solid foundation in numerical methods, optimization, controls, and engineering model validation.
• Excellent communication and collaboration skills, with the ability to influence cross-functional engineering decisions through quantitative analysis.
• Ability and willingness to work onsite with cross-functional engineering teams. This role requires regular hands-on collaboration with hardware, testing, and flight operations.

 Preferred Qualifications

• M.S. or Ph.D. in Electrical Engineering, Mechanical Engineering, Aerospace Engineering, or a related field.
• Experience using high-fidelity electromagnetic and thermal simulation tools such as ANSYS Motor-CAD, ANSYS Maxwell, JMAG, COMSOL, ANSYS Icepak, or similar.
• Familiarity with production telemetry, fleet operations, or hardware test data for engineering model validation and continuous improvement.

What Else You Need To Know

The starting salary range for this role is $145,000 - $185,000. Zipline is an equal opportunity employer and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws or our own sensibilities.

We value diversity at Zipline and welcome applications from those who are traditionally underrepresented in tech. If you like the sound of this position but are not sure if you are the perfect fit, please apply!