UAS Integration Engineer

The UAS Integration Engineer is primarily responsible for UAS payload integration and UAS mechanical design, supporting the design, prototyping, integration, and testing of Unmanned Aircraft Systems (UAS) and their payloads for government programs, with an emphasis on Group 1 and Group 2 platforms. The role combines hands-on mechanical design with cross-disciplinary integration work, blending the responsibilities of a design engineer with those of a UAS systems specialist. Candidates must be competent in CAD and CAM software (SolidWorks, Fusion 360), hold a Mechanical or Electrical Engineering degree, and be open to travel up to 25%.

Working alongside senior engineers and within our rapid-prototyping facility, you will take payloads and subsystems from concept through CAD modeling, fabrication, fit-up, and physical integration onto airframes across lab, shop, and field environments. This is a growth-oriented position for an engineer early in their career who wants to build deep, practical UAS expertise. Early on, you’ll execute well-scoped design and integration tasks; over time, you’ll grow into owning payload integration efforts end to end and taking on broader systems responsibility.

This is not a remote position; the selected candidate will be required to work onsite in Port Orange, FL., * Mechanical Design: Design UAS structures, mounts, brackets, enclosures, and payload interfaces using CAD software (SolidWorks, Fusion 360), accounting for weight, balance, and structural integrity.

• Payload Integration: Integrate payloads-sensors, EO/IR cameras, communications equipment, radios, antennas, and mission-specific hardware-onto Group 1 and Group 2 UAS platforms, ensuring mechanical fit and electrical compatibility.
• Rapid Prototyping: Support quick-turn design, prototyping, and iteration of UAS solutions using CAM software to prepare parts for machining, 3D printing, and fabrication.
• DFM/DFA: Apply Design for Manufacturability and Design for Assembly principles to reduce cost and complexity while improving quality and reliability.
• Field Support: Travel to test sites, customer locations, and demonstrations to support integration and evaluation activities (approximately 25%).

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or a related discipline (Aerospace Engineering also applicable).
• 2+ years of relevant engineering experience; strong recent graduates with significant project, internship, or hands-on UAS/robotics experience will be considered.
• Demonstrated competency in CAD and CAM software, specifically SolidWorks and/or Fusion 360.
• Solid grasp of mechanical design fundamentals, tolerancing, and design for manufacturability and assembly.
• Basic mechanical and electrical aptitude, including comfort with hand tools, test equipment, soldering, and wiring.
• Highly organized and deadline-driven, with strong attention to detail and the ability to manage multiple integration tasks at once.
• Clear written and verbal communication skills.
• Willingness and ability to travel up to 25%.
• Ability to obtain and maintain a Secret (Tier 3) security clearance as required by contract or program needs.

Preferred Experience/Qualifications

• Hands-on experience with UAS, drones, or other unmanned and robotic platforms (academic, professional, or hobbyist).
• Familiarity with Group 1 and Group 2 UAS platforms and applicable DoD/FAA categorization.
• Experience with Autodesk Inventor in addition to SolidWorks/Fusion 360.
• Familiarity with rapid prototyping, 3D printing, or CNC machining.
• Basic understanding of RF, communications links, GPS/GNSS, or telemetry concepts.
• FAA Part 107 Remote Pilot Certificate, or willingness to obtain one.

Special Requirements/Security Clearance

• Ability to obtain and maintain a DoD Secret (Tier 3) clearance.
• Up to 25% travel to support program objectives and customer engagements.

By Light Professional IT Services LLC readies warfighters and federal agencies with technology and systems engineered to connect, protect, and prepare individuals and teams for whatever comes next. Headquartered in McLean, VA, By Light supports defense, civilian, and commercial IT customers worldwide.