As a UAS Design and Integration Engineer at APL, you will own the design and integration of uncrewed air system prototypes from concept through delivery, including hands-on assembly, testing, and failure analysis. You will collaborate across multidisciplinary teams to translate mission needs into practical, low-cost solutions and drive iterative improvements based on test data. The role focuses on building and integrating complete systems that perform reliably in realistic operational environments.

Responsibilities

Own the design and integration of UAS prototypes from concept development and trade studies through build, laboratory checkout, ground and flight testing, failure investigation, redesign, and delivery to test teams and end users.
Lead and participate in the hands-on assembly and integration of UAS platforms, including composite fabrication and repair, component installation, custom wiring harness fabrication, soldering, propulsion systems, sensors, and payload integration.
Translate mission needs and operational constraints into practical, low-cost vehicle, payload, avionics, propulsion, and ground support solutions while balancing performance, mass, power, cost, schedule, reliability, safety, maintainability, and field repairability.
Collaborate across mechanical, electrical, software, autonomy, test, and operations teams to ensure design decisions support the performance of the complete integrated system rather than an isolated subsystem.
Design and integrate flight control systems, including autopilot configuration, sensor calibration, and GNC tuning to optimize flight performance across conventional and nontraditional UAS configurations.
Plan, coordinate, and execute laboratory, ground, and flight testing; analyze results; identify root causes; and drive iterative design improvements based on test data and operational feedback.
Communicate technical risks, design issues, integration challenges, and schedule impacts early, and help drive corrective actions through the next build, test, or field event.
Produce practical documentation that enables teammates to build, test, operate, maintain, repair, and improve the system, including as-built configurations, test procedures, checklists, and lessons learned.

Requirements

Have a Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Electrical Engineering, or a related engineering field.
Have demonstrated professional, military, or substantial hands-on project experience designing, building, integrating, and testing custom uncrewed aerial systems, aircraft, robotics, or other complex hardware systems deployed for users, operators, customers, or mission demonstrations.
Have experience owning technical solutions through build, testing, troubleshooting, and iterative improvement—not solely analysis or design handoff.
Have experience designing, integrating, operating, and troubleshooting complex mechanical and electrical aerospace, robotic, or prototype systems.
Are proficient with modern UAS autopilot systems (e.g., PX4, ArduPilot) and their associated ground control software.
Have a strong understanding of UAS subsystems, including avionics, propulsion, GNC, electrical systems, payload integration, and hardware interfaces.
Communicate effectively across mechanical, electrical, software, test, and operations disciplines, and make design decisions that support the performance of the integrated system.
Enjoy working hands-on in laboratories, machine shops, and field environments, and are comfortable moving between engineering design, prototype fabrication, system integration, testing, and failure investigation.
Hold an active Secret security clearance and can ultimately obtain a TS/SCI level clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship.

Nice to have

Have 3+ years of relevant professional experience with integrated flight systems, UAS development, or prototype hardware.
Have led or made significant technical contributions to multiple prototype build-test-learn cycles and can describe key failures, corrective actions, and resulting improvements.
Hold a current FAA Part 107 Remote Pilot Certificate and have significant flight experience across multiple UAS platforms.
Possess extensive experience integrating avionics, including the selection, installation, checkout, and troubleshooting of sensors, flight computers, communications equipment, and other flight hardware.
Demonstrate strong experience tuning flight control systems (GNC), particularly for unconventional or VTOL aircraft.
Are proficient with CAD software (e.g., SolidWorks) for component design, packaging, integration planning, and rapid design iteration.
Have experience designing systems for low-cost manufacturing, rapid repair, field modification, maintainability, or low-volume production.
Have supported field testing or flight operations where hardware readiness, logistics, schedule pressure, operators, and evolving prototype hardware had to be managed simultaneously.
Have experience developing CONEMPs (Concepts of Employment) and mission system architectures for UAS.
Hold an active TS/SCI security clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship.

Benefits

At APL, we celebrate our differences of perspectives and encourage creativity and bold, new ideas. Our employees enjoy generous benefits, including a robust education assistance program, unparalleled retirement contributions, and a healthy work/life balance. APL’s campus is located in the Baltimore-Washington metro area. Learn more about our career opportunities at https://www.jhuapl.edu/careers.
The referenced pay range is based on JHU APL’s good faith belief at the time of posting. Actual compensation may vary based on factors such as geographic location, work experience, market conditions, education/training and skill level with consideration for internal parity. For salaried employees scheduled to work less than 40 hours per week, annual salary will be prorated based on the number of hours worked. APL may offer bonuses or other forms of compensation per internal policy and/or contractual designation. Additional compensation may be provided in the form of a sign-on bonus, relocation benefits, locality allowance or discretionary payments for exceptional performance. APL provides eligible staff with a comprehensive benefits package including retirement plans, paid time off, medical, dental, vision, life insurance, short-term disability, long-term disability, flexible spending accounts, education assistance, and training and development. Applications are accepted on a rolling basis.