17 Flight Test Engineer Interview Questions and Answers

Aerospace engineering is a highly technical field that deals with the design, development, testing, and production of aircraft and spacecraft. Flight test engineers are a specialized subgroup within this field whose job is to, you guessed it, test aircraft and spacecraft to make sure they meet all the necessary safety and performance standards before they’re cleared for takeoff.

If you’re interested in becoming a flight test engineer, you’ll need to have a strong foundation in mathematics and science, as well as excellent problem-solving skills. You’ll also need to be able to think quickly on your feet and be able to make decisions under pressure.

Proving that you have what it takes to be a flight test engineer starts with nailing your interview. To help you prepare, we’ve put together a list of common flight test engineer interview questions and sample answers.

Are you comfortable working with a team of engineers to design and build prototypes?

The interviewer may ask this question to learn more about your teamwork skills and how you interact with other engineers. Your answer should include an example of a time when you collaborated with others on a project, such as a team meeting or conference call where you shared your ideas and opinions.

Example: “I have worked in teams before, including my current position at the aerospace engineering firm. In my last role, I was part of a team that met once a week to discuss our progress on projects. During these meetings, we would share what we accomplished during the previous week and any challenges we faced. We also discussed new ideas for improving our prototypes and brainstormed ways to implement them.”

What are some of the most important skills you have that make you a good flight test engineer?

This question can help the interviewer get to know you as a person and how your skills fit into this role. Use examples of your technical, communication or problem-solving skills that will benefit you in this position.

Example: “I have excellent attention to detail, which is important for flight test engineers because we need to make sure all data is recorded correctly. I also have strong problem-solving skills, so if something goes wrong during a test, I can work with my team to find solutions quickly. Finally, I am very good at communicating with others, especially when there are problems or questions about the tests.”

How would you conduct a test to determine if an aircraft can withstand a bird strike?

The interviewer may ask you a question like this to assess your problem-solving skills and ability to apply engineering principles. In your answer, describe the steps you would take to conduct such a test and how you would use data from the test to determine if an aircraft can withstand a bird strike.

Example: “To determine if an aircraft can withstand a bird strike, I would first identify the type of bird that could potentially strike the plane. Then, I would perform a stress analysis on the aircraft’s fuselage to see if it can withstand the impact of the bird. I would also consider other factors that could affect the outcome of the test, such as wind speed and direction, temperature and humidity. After conducting the test, I would analyze the results and compare them with industry standards to determine if the aircraft can withstand a bird strike.”

What is your process for determining if a prototype is ready for a test flight?

Interviewers may ask this question to learn more about your process for testing prototypes and how you determine when a prototype is ready for flight. Use your answer to highlight your critical thinking skills, problem-solving abilities and ability to make decisions under pressure.

Example: “I use my engineering knowledge and experience to assess the safety of each prototype before I allow it to fly. When determining if a prototype is ready for test flight, I first look at all of the data from previous tests. If there are any issues with the prototype that could affect its performance during flight, I address those issues before allowing the prototype to take off. I also consider the weather conditions on the day of the test flight as well as the pilot’s skill level.”

Provide an example of a time when you identified and resolved a design flaw in an aircraft prototype.

An interviewer may ask this question to learn more about your problem-solving skills and ability to identify design flaws in aircraft prototypes. Use examples from your experience as a flight test engineer that show you can recognize potential problems with an aircraft’s design and implement solutions to resolve them.

Example: “In my previous role, I was responsible for testing the prototype of a new aircraft model before it went into production. During one of our initial tests, we noticed that the landing gear on the plane would not retract properly when the pilot lowered it. This could have been dangerous if the pilot needed to land the plane during a flight. After inspecting the plane further, I realized that the locking mechanism on the landing gear had malfunctioned. We fixed the issue by replacing the faulty part.”

If you were conducting a test flight and the aircraft started to behave abnormally, what would be your top priority?

This question is designed to assess your ability to prioritize under pressure. Your answer should show that you can make quick decisions and act on them effectively.

Example: “If the aircraft started behaving abnormally, my first priority would be to ensure the safety of everyone onboard. I would immediately check all the gauges and instruments to determine what was causing the problem. If it was something minor, like a loose wire or faulty sensor, I could fix it myself. However, if it was something more serious, such as an engine malfunction, I would have to abort the flight and return to base.”

What would you do if you identified a flaw in an aircraft’s design after it had already been put into production?

This question can help the interviewer assess your problem-solving skills and ability to work within a team. Your answer should show that you are willing to take responsibility for your actions, even if they lead to negative outcomes.

Example: “If I identified a flaw in an aircraft’s design after it had already been put into production, I would first try to determine whether or not this flaw could be fixed without having to recall the entire fleet of planes. If I determined that there was no way to fix the flaw without recalling all of the planes, I would immediately inform my supervisor so that we could begin the recall process as soon as possible. This is because I understand that any flaws in an aircraft’s design must be addressed before putting the plane into production.

How well do you think you would be able to communicate with pilots and other members of an aircraft crew to relay important information?

The interviewer may ask you a question like this to assess your communication skills and how well you can work with others. Use examples from past experiences where you had to communicate important information to pilots or crew members, such as during pre-flight checks or in the cockpit.

Example: “I think my communication skills are one of my strongest abilities. In my last position, I was responsible for communicating flight plans to pilots before takeoff. During these briefings, I would explain any changes to the plan and relay instructions on what they should expect during the flight. Pilots appreciated that I could clearly convey all necessary information without confusing them.”

Do you have experience using computer-aided design software to create prototypes?

The interviewer may ask you a question like this to learn more about your experience using specific software programs. If they ask you about your experience with computer-aided design (CAD) software, consider mentioning the name of the program and how long you’ve used it. You can also share an example of a project you completed while using CAD software.

Example: “I have extensive experience using Autodesk Inventor Professional software to create prototypes for my projects. I first learned how to use this program in college when I took a class on engineering design. Since then, I’ve used this program to complete several projects at my current job, including designing new parts for airplanes.”

When conducting tests on prototypes, do you have a process for documenting your findings?

Interviewers may ask this question to understand how you organize your work and the level of detail you provide in your documentation. In your answer, describe a time when you documented findings from testing prototypes and highlight any specific skills or techniques that helped you complete your work efficiently.

Example: “I have found it helpful to use software programs for documenting my test results. I find that using these programs allows me to create detailed reports with images and diagrams that help other engineers replicate my tests. When conducting flight tests on prototypes, I always take notes during each phase of the test so I can document all relevant information about the prototype’s performance.”

We want to ensure that our aircraft designs are as safe as possible. How would you go about conducting a test that simulates a crash landing?

The interviewer may ask you a question like this to assess your knowledge of the company’s safety standards and how you would apply them in your work. In your answer, explain what steps you would take to ensure that the test was as accurate as possible and describe any specific tools or processes you would use to conduct it.

Example: “I would first make sure that all personnel were out of the aircraft before I started the simulation. Then, I would run through the entire flight plan, including takeoff, cruising and landing. During each phase, I would check for any potential issues with the design, such as loose parts or faulty wiring. After completing the simulation, I would review the data and compare it to our safety standards.”

Describe your process for ensuring that an aircraft prototype can withstand extreme temperatures and other environmental conditions.

The interviewer may ask you a question like this to assess your problem-solving skills and ability to apply engineering principles to real-world situations. In your answer, describe the steps you take to ensure that an aircraft prototype can withstand extreme temperatures and other environmental conditions.

Example: “I first conduct a thorough analysis of the materials used in the construction of the aircraft’s exterior and interior components. I then calculate the weight of the aircraft based on its size and determine whether it will be able to support itself during flight. Finally, I test the aircraft under various temperature and pressure conditions to ensure that it can withstand these conditions.”

What makes you the best candidate for this flight test engineer position?

This question is your opportunity to show the interviewer that you are qualified for this role. Use examples from your experience and education to highlight your skills, knowledge and abilities.

Example: “I am a highly organized person who can work well under pressure. I have extensive flight test engineering experience in my current position, where I’ve worked with several different teams of engineers on various projects. My ability to communicate clearly and effectively has helped me manage these large groups of people and ensure everyone understands their roles and responsibilities.”

Which aircraft designs are you most familiar with?

The interviewer may ask this question to determine your level of experience with aircraft designs. If you have previous flight test engineer experience, the interviewer may want to know which types of aircraft you’ve worked on in the past. You can answer honestly about the aircraft you’ve worked on and explain why they were important to you or what you learned from them.

Example: “I’m most familiar with commercial airliners because I spent five years working as a flight test engineer for an airline company. During my time there, I helped design new planes that could fly longer distances while using less fuel. This was challenging but rewarding work, and I learned how to apply engineering principles to real-world situations.”

What do you think is the most important aspect of your job as a flight test engineer?

This question can help the interviewer understand what you value most in your work. Your answer can also tell them about how you prioritize your tasks and goals. When answering this question, it can be helpful to think about which aspects of flight test engineering you enjoy the most.

Example: “I believe that safety is the most important aspect of my job as a flight test engineer. I take pride in knowing that my work helps ensure the safety of pilots and passengers during testing flights. It’s rewarding to know that our company’s products are safe for use by the public. I always strive to make sure all of my tests meet or exceed industry standards.”

How often do you think aircraft designs should be tested to ensure safety?

The interviewer may ask you this question to understand your testing philosophy. Your answer should show that you are aware of the importance of safety and how it relates to aircraft design. You can use examples from your experience to explain why you think testing is important.

Example: “I believe that aircraft designs should be tested as often as possible, especially when they’re new or have been significantly altered. I’ve seen situations where a test was skipped because an engineer thought there wasn’t anything wrong with the plane. However, during flight, the plane experienced problems that could have been avoided if the engineer had performed more tests.”

There is a new design that you’re unfamiliar with. How would you prepare for your role as a flight test engineer on this project?

This question can help the interviewer understand how you approach new projects and challenges. Use your answer to highlight your problem-solving skills, ability to learn quickly and willingness to ask for help when needed.

Example: “I would first read through all of the specifications that were given to me by my team leader or supervisor. I would then research any questions I have about the design so that I could fully understand it before testing it in a flight test. This way, I can ensure that I am asking relevant questions during the test and getting answers from my colleagues as soon as possible.”