ESC Design Engineer

Join the Team Building the Future of Flight

Are you looking for an opportunity to make a real impact, take on exciting challenges, and be part of a team that's shaping the future of aviation?

At Malloy Aeronautics, you'll play a key role in helping us develop innovative technology that's changing the way the world moves.

Who are we?

We're on a mission to revolutionise unmanned flight. At Malloy Aeronautics, we develop advanced heavy-lift UAVs for both defence and commercial applications.

What sets us apart is our in-house approach. From design and engineering to manufacturing and testing, the majority of our work happens under one roof in Berkshire, allowing us to innovate quickly, maintain exceptional quality, and bring ideas to life faster.

For our teams, that means hands-on involvement, real ownership, and the opportunity to help shape the future of aviation.

What are we looking for?

Malloy Aeronautics is looking for an ESC Design Engineer with experience in power electronics and motor control to support the development of advanced UAV propulsion systems. This role is ideal for an engineer who enjoys hands-on design, testing and integration, and wants to help deliver innovative aerospace technology.

Ability to hold Security Clearance – 5 years residence in the UK

What You’ll Being Doing (but Not Limited Too)

Design and develop ESC hardware for brushless DC and PMSM motors, including power stage, gate drivers, and protection and control circuits

Define and implement control algorithms (e.g. FOC, trapezoidal, sensorless) in collaboration with embedded software teams

Select and validate components to meet thermal, electrical, and EMI/EMC constraints for UAV applications

Conduct simulations (e.g. SPICE, ANSYS) to evaluate circuit behaviour, efficiency, and thermal performance

Create schematics and PCB layouts optimised for high-current, high-frequency switching applications

Validate ESC performance through bench tests, HIL setups, and full propulsion system integration

Support fault diagnosis, root cause analysis, and design improvements in both R&D and production contexts

Work with thermal and mechanical engineers to define heatsinking, packaging, and environmental protection solutions

Document design decisions, test results, and compliance evidence for quality and traceability

Contribute to design-for-manufacture and design-for-assembly improvements for ESC production scaling

Design and development of ESC test systems

Essential Skills And Experiences

Strong knowledge of motor control theory and ESC topologies (e.g. field-oriented control, BLDC 6-step trapezoidal control)

Deep understanding of power electronics components (MOSFETs, gate drivers, capacitors, inductors, current sensors)

Understanding of thermal management, EMI mitigation, and PCB layout strategies for high-power systems

Awareness of UAV propulsion system requirements and constraints (weight, efficiency, safety)

Good understanding of wide band gap devices (e.g. SiC, GaN)

Desired Skills And Experiences

Proficient in schematic capture and PCB design using tools such as Altium or KiCad

Skilled in simulating and analysing power electronics systems for performance and reliability

Hands-on experience with laboratory testing, using oscilloscopes, power analysers, and motor rigs

Clear technical communicator capable of producing thorough documentation and test reports

Detail-oriented, methodical, and safety-conscious in working with high-voltage and high-current systems

Able to collaborate across disciplines and support real-world system integration and troubleshooting

Writing risk assessments to determine best working practices

Task flexibility – adaptive planning

Benefits You May Be Eligible For

Alternate Fridays off with our 9-day fortnight

BAE Systems Share Incentive Plan

5% employer pension contribution

Annual collective incentive bonus scheme

Enhanced family leave with 6 months' full-pay maternity leave and 4 weeks' full-pay paternity leave

20 days' annual leave, increasing with service, plus a 3-day Christmas shutdown

Company sick pay

Healthcare Cash Plan with Virtual GP access, dental and optical support, plus free cover for dependent children up to age 24

Mental health and wellbeing support available 24/7

Cycle to Work Scheme

Proud supporter of the Armed Forces through our Bronze Armed Forces Covenant commitment.

Malloy Aeronautics employees will be subject to both security and export control restrictions. These restrictions mean that factors including your nationality, any previous nationalities you have held, and your place of birth may limit those roles you can perform for the organisation.

We’re committed to building an inclusive workplace where everyone feels valued and supported. We know that a diversity of backgro

unds, perspectives and experiences strengthens our teams and is vital to the work we do.

Please be aware that many roles at Malloy Aeronautics are subject to both security and export control restrictions. These restrictions mean that factors such as your nationality, any nationalities you may have previously held, and your place of birth can restrict the roles you are eligible to perform within the organisation. All applicants must as a minimum achieve Baseline Personnel Security Standard. Many roles also require higher levels of National Security Vetting where applicants must typically have 5 to 10 years of continuous residency in the UK depending on the vetting level required for the role, to allow for meaningful security