Principal Hardware-in-the-Loop Engineer

• CHAOS is seeking a Principal Hardware-in-the-Loop (HIL) Engineer to lead the architecture, development, and deployment of advanced HIL simulation environments supporting high-reliability effector platforms
• This role is responsible for defining scalable, high-fidelity validation frameworks that enable full system integration testing across multiple programs-bridging software, autonomy, and flight hardware
• This position spans the full lifecycle of HIL development, from early requirements shaping and simulation architecture through hardware/software integration, automated test development, system validation, and transition to flight test
• Lead the architecture, design, and development of HIL test benches for full effector system integration, including flight controllers, ESCs, sensors, and ground control systems
• Define HIL strategy, fidelity requirements, and validation approaches to ensure comprehensive system-level test coverage prior to flight
• Establish reusable approaches for HIL system design, model integration, and test automation across programs
• Architect and integrate high-fidelity simulation models (flight dynamics, actuator, and sensor models) that accurately replicate real-world behavior
• Lead integration of hardware components into HIL systems, including flight computers, ESCs, communication links, sensors, and power systems
• Drive development of automated test frameworks, regression infrastructure, and CI/CD integration for continuous validation of software and firmware
• Guide debugging and root cause analysis of complex hardware-software interactions using HIL data, logs, and telemetry
• Collaborate with GNC, software, and systems engineering teams to define verification strategies, test plans, and acceptance criteria across programs
• Own, maintain, and improve test infrastructure, including simulation software, real-time targets, and data acquisition systems
• Document test methodologies, procedures, and results clearly for cross-functional team use
• Support transition of HIL-validated systems to integration and flight test phases

Skills & expertise Continuous integration Collaboration and teamwork C++ Matlab Linux, * The ideal candidate is a highly experienced, hands-on engineer who can lead complex HIL efforts, guide other engineers, and ensure consistent, high-quality validation approaches across programs

• Experience with version control systems and CI/CD pipelines for automated testing
• Strong analytical, debugging and root cause analysis skills across hardware, software, and simulation domains
• Demonstrated ability to lead technical efforts and guide engineers through complex integration and troubleshooting challenges
• 10+ years of experience in hardware-in-the-loop testing, embedded systems integration, or a closely related discipline
• Solid understanding of effector system architecture, including propulsion, navigation, and control loops
• Strong programming skills in Python and/or C/C++ for test automation and system scripting
• Hands-on experience building and operating HIL or SIL simulation environments for embedded or autonomous systems
• Bachelor's degree in Engineering, Computer Science, or a related field
• Ability to obtain and maintain a U.S. security clearance
• Experience with communication protocols common in drone systems (MAVLink, CAN, UART, SPI, I2C)
• Familiarity with flight controller software such as PX4, ArduPilot, or equivalent
• Proficiency in real-time simulation platforms (e.g., dSPACE, NI VeriStand, or similar)
• Advanced degree (MS or PhD) in Engineering or related field
• Experience with ROS or ROS 2 for simulation and integration testing
• Strong background in flight dynamics, control systems, or GNC model development (MATLAB/Simulink or similar)
• Experience correlating simulation environments with real-world flight test data
• Familiarity with FPGA-based simulation, embedded Linux systems, or real-time computing architectures
• Experience with RF systems, GPS signal simulation, or sensor fusion validation
• Experience establishing reusable simulation frameworks or model libraries across programs
• Exposure to flight test operations and transitioning systems from HIL to field testing
• FAA Part 107 certification or equivalent UAV operational credentials

• Generous pre-IPO stock option grants, relocation assistance + (coming soon!) annual bonuses
• Free daily lunch, 'No meeting Fridays', unlimited PTO (for exempt employees), casual dress code
• Life, FSA, HSA, 401k (+ Company match), and more
• Medical, dental and vision benefits will be 100% paid for by the company