AI-Driven Hardware Test & Prototype Engineer

SiFly; Santa Clara (CA); On-site; USD 90,000 - 140,000; Full time

Job summary

SiFly Aviation in Santa Clara, CA is seeking a Hardware Test & Prototype Engineer to turn concepts into working hardware for our vertical-takeoff, long-endurance drones. You will design and assemble prototypes, instrument systems, run tests, document failures, and keep test assets reliable.

This role blends hands-on fabrication with rigorous documentation and problem-solving in a fast-paced environment. You will work onsite, collaborating with a small team to push hardware from concept to

Qualifications

• Hands-on electromechanical build experience with mechanisms, harnesses, sensors and test fixtures.
• Ability to read engineering drawings, CAD views, BOMs and wiring diagrams.
• Proficient in instrumentation and data acquisition for reliable measurements.
• Shop fabrication capability for fixtures and brackets.
• Strong judgment to interpret intent and adapt when procedures don’t cover it.
• Disciplined record-keeping of serial numbers, firmware, configs and conditions.
• Safe around heavy assemblies and outdoor test environments.
• Experience applying AI tools to improve workflows and data handling.

Responsibilities

• Assemble, integrate, rework, and maintain prototypes and test articles including structures, motors, sensors, and harnesses.
• Fabricate and modify components, fixtures, and test equipment using shop tools.
• Build, route, terminate, and troubleshoot wiring harnesses and electromechanical connections.
• Instrument test articles with sensors and data acquisition equipment.
• Set up automated cycle testers and environmental test rigs.
• Execute tests to approved procedures and safety requirements.
• Monitor tests, identify anomalies, and escalate when unsafe.
• Record configurations and observations with photos and logs for investigations.
• Distinguish failures from fixture or operator issues and reproduce field faults in lab.
• Support hardware builds for validation and deployment sites; prepare tools and spares.
• Share AI-assisted approaches to debugging and documentation with the team.

Skills

Electromechanical build

Engineering drawings

Data acquisition

Shop fabrication

Problem solving

Documentation

Safety awareness

AI in workflow

Job description

SiFly Aviation in Santa Clara, CA is seeking a Hardware Test & Prototype Engineer to turn concepts into working hardware for our vertical-takeoff, long-endurance drones. You will design and assemble prototypes, instrument systems, run tests, document failures, and keep test assets reliable.

This role blends hands-on fabrication with rigorous documentation and problem-solving in a fast-paced environment. You will work onsite, collaborating with a small team to push hardware from concept to