UAV Propulsion System Design and Development

Freelance Power Electronics Engineer – 12S 80A UAV ESC Development Company: Aerionix Project Type: Contract / Milestone-Based Industry: UAV Propulsion Systems Aerionix is developing next-generation high-efficiency propulsion systems for UAV applications. We are looking for an experienced Power Electronics Engineer to design and develop a high-performance 80A, 12S (48V) Electronic Speed Controller (ESC) comparable to industry-grade solutions used with motors such as the T-Motor AG8014. This is a serious high-power electronics project — not hobby-level ESC development. Project Objective Design, prototype, and validate a 48V (12S LiPo), 80A continuous ESC optimized for UAV propulsion with: ≥97% target efficiency FOC (Field Oriented Control) preferred 80A continuous, 100A peak capability Robust protection systems Telemetry support (UART/CAN preferred) Production-ready PCB design Required Expertise High-voltage power electronics (48–60V systems) 3-phase inverter design MOSFET selection & gate driver optimization FOC implementation experience STM32 / TI C2000 / equivalent MCU High-current PCB layout (4-layer preferred) EMI/EMC mitigation Thermal design & power loss calculations UAV ESC firmware experience (DShot/PWM) Scope of Work (Milestone-Based) Phase 1 – System Architecture & Component Selection Topology selection MOSFET & driver selection Current sensing strategy Thermal & loss calculations Complete architecture document Phase 2 – Schematic & PCB Design Full power + control schematic 4-layer optimized PCB layout EMI & thermal consideration Manufacturing-ready Gerbers Phase 3 – Firmware Development Basic motor spin (6-step) Current limiting FOC implementation Control loop tuning Protection systems Phase 4 – Testing & Validation 80A load testing Thermal validation Protection validation Performance documentation Deliverables Full source files (Altium/KiCad) Firmware source code BOM with part numbers Test reports & validation data Production-ready manufacturing files Important Terms NDA required Full IP ownership transferred to Aerionix Milestone-based payments Prior similar ESC experience preferred Ideal Candidate Has designed ESCs above 60V Has shipped high-current power electronics products Can demonstrate previous inverter/ESC designs Strong understanding of UAV propulsion systems If you have built high-performance ESCs or 3-phase motor controllers in the 48V+ range, we would like to review your portfolio and discuss technical approach before engagement. Please share: Relevant past projects by MCU platform experience Power level previously handled Estimated timeline

Projekt-ID: 40258349