Drone Design and Integration Engineer | UAS and Autonomous Systems

XCaliber Technologies; Norwalk (CT); On-site; USD 95,000 - 130,000; Full time

Job summary

XCaliber Technologies is actively seeking two hands-on engineers to design, build, integrate, and test unmanned aircraft platforms. You will translate CAD designs into physical prototypes, select components, and assemble devices for flight testing and production readiness.

You will work closely with autonomy, controls, and embedded software teams to resolve integration issues, perform bench tests, and iterate designs based on flight data. This role emphasizes workshop time and field testing.

Qualifications

• Strong mechanical fundamentals and practical CAD skills.
• Hands-on experience designing, building, integrating, and testing drones or complex hardware.
• Understanding of mechanical and electrical integration with tradeoffs across weight, power, performance, reliability, and cost.
• Comfort with mechanical assembly, soldering, wiring, battery handling, and basic electrical measurement.
• Familiarity with prototyping methods such as 3D printing, machining, or composites.
• Ability to interpret test data, investigate failures, and own resolution of problems.

Responsibilities

• Design airframes, structures, mounts, and mechanisms in CAD and prototype.
• Develop aircraft layouts balancing weight, CG, performance, cooling, serviceability, and manufacturability.
• Select and integrate propulsion, batteries, control systems, avionics, sensors, and payloads.
• Build complete prototype aircraft, including mechanical assembly and wiring.
• Configure flight controllers and onboard electronics, tuning and integration with leads.
• Conduct bench/ground tests and participate in flight testing; diagnose failures and improve designs.
• Collaborate with autonomy, controls, embedded software, electrical, and manufacturing teams to resolve integration issues.
• Maintain drawings, BOMs, build instructions, configuration records, and test notes.

Skills

CAD

Drones / unmanned systems

Mechanical design

Electrical integration

Soldering

Education

Mechanical Engineering

Aerospace Engineering

Electrical Engineering

Robotics

Mechatronics

Tools

3D printing

Machining

Electrical testing equipment

Job description

XCaliber Technologies is a defense technology company building the next generation of autonomous air defense. We develop integrated Counter UAS systems combining autonomy, sensing, command and control, and purpose built aircraft to detect, track, and defeat evolving aerial threats.

We are a small, fast moving team where your work directly shapes the aircraft we build and the capabilities we deliver to protect people and strengthen national security.

The Role

We are hiring two hands on engineers to design, build, integrate, and test our unmanned aircraft platforms.

You will work across the complete aircraft, taking designs from CAD and component selection through assembly, configuration, ground and flight testing, and production readiness. The role involves substantial time in the workshop and test field, working directly with our engineering leads to turn concepts into reliable, repeatable hardware.

What You Will Do

• Design airframes, structures, mounts, and mechanisms in CAD, and get them made through prototyping, fabrication, and suppliers.


• Develop aircraft layouts that balance weight, center of gravity, structural performance, cooling, serviceability, and manufacturability.


• Select and integrate propulsion, batteries, power electronics, flight controllers, avionics, sensors, communications, and payloads based on performance, compatibility, availability, and cost.


• Build complete prototype aircraft, including mechanical assembly, wiring harnesses, soldering, and cable management.


• Configure and validate flight controllers and onboard electronics, working with engineering leads on tuning and integration.


• Conduct bench and ground tests and participate in flight testing. Analyze results, diagnose failures, fix root causes, and improve designs.


• Work closely with autonomy, controls, embedded software, electrical, and manufacturing engineers to resolve integration issues across the aircraft.


• Maintain engineering drawings, bills of materials, build instructions, configuration records, and test notes so aircraft can be built and tested consistently.

What We Are Looking For

• Strong mechanical engineering fundamentals and practical CAD skills.


• Hands on experience designing, building, integrating, and troubleshooting drones, robotic systems, or other complex hardware through repeated development and testing cycles.


• Understanding of mechanical and electrical integration, with the ability to make practical tradeoffs across weight, power, performance, reliability, and cost.


• Comfort with mechanical assembly, soldering, wiring, battery handling, and basic electrical measurement.


• Familiarity with manufacturing and prototyping methods such as 3D printing, machining, or composite fabrication.


• Ability to interpret test data, investigate failures, document changes, and take ownership of problems through resolution.


• Willingness to work directly with hardware and participate in field testing as part of a small engineering team.


• A degree in Mechanical Engineering, Aerospace Engineering, Electrical Engineering, Robotics, Mechatronics, or a related field, or equivalent demonstrated experience.

Nice to Have

• Experience designing, building, and flying multirotor, fixed wing, or other unmanned aircraft.


• Familiarity with autopilot platforms such as PX4, ArduPilot, or Betaflight.


• Experience with electric propulsion, lightweight structures, composites, aircraft sensors, payload integration, or radio frequency systems.


• Programming or scripting skills in Python, C, or C++ for testing, analysis, or integration.


• A Federal Aviation Administration (FAA) Part 107 remote pilot certificate or practical flight testing experience.

Direct defense or Counter UAS experience is valuable but not required.

Show Us What You Have Built

We welcome examples from professional, academic, or personal projects, including photos, videos, CAD work, build logs, or test results. If your work is confidential, you can discuss your contribution, engineering decisions, and lessons learned at an appropriate level.

We care about your ability to build, test, learn, and solve difficult engineering problems.