Lead Hardware Design Engineer, sUAS

Colsa-5; Madison (AL); On-site; USD 120,000 - 170,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

401(k) with company match

Education Reimbursement

Job summary

COLSA Corporation is seeking a Lead Hardware Design Engineer with strong sUAS hardware experience to provide technical leadership across the full hardware lifecycle from concept to sustainment.

You will guide engineers and technicians, create 3D models and manufacturing docs, and ensure designs meet performance, reliability, and cost targets while coordinating with cross‑functional teams for integration and testing.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Hardware Engineering, Aerospace Engineering, Electrical Engineering, or a related technical discipline, or equivalent experience.
• Minimum of 10-16 years of related experience
• Demonstrated expertise with SolidWorks CAD and SolidWorks PDM
• Hands‑on experience with 3D modeling, additive manufacturing, including 3D printing, rapid prototyping, and design
• Demonstrated ability to evaluate and balance competing system‑level constraints during the design, integration, and testing of uncrewed systems to meet customer needs
• Proven ability to lead and mentor multidisciplinary engineering teams in fast‑paced uncrewed systems design, testing, and field environments
• Experience overseeing multiple complete product development lifecycles for an uncrewed aerial system, from concept through completion
• U.S. Citizenship required; selected candidate must successfully complete a criminal background check prior to the start date

Responsibilities

• Design, develop, and support hardware solutions for small Uncrewed Aircraft Systems (sUAS), including airframes and related components.
• Provide technical guidance and work leadership to junior design engineers and engineering technicians throughout the full production lifecycle.
• Create and maintain 3D models, assemblies, engineering drawings, and manufacturing documentation.
• Manage engineering documentation, revisions, and product configurations using SolidWorks PDM.
• Develop and build prototype hardware using 3D printing and other rapid prototyping methods.
• Evaluate hardware designs to ensure they meet performance, reliability, manufacturability, and cost objectives.
• Support hardware integration, assembly, testing, and validation throughout the development lifecycle.
• Develop and execute hardware test plans, document results, and recommend design improvements based on test findings.
• Collaborate with electrical, software, systems, manufacturing, and test engineers to support successful system integration and product development.
• Prepare engineering documentation, including technical reports, work instructions, and test procedures.
• Apply engineering principles to identify, troubleshoot, and resolve technical challenges while balancing performance, schedule, cost, and mission requirements.
• Participate in design reviews, technical meetings, and customer briefings.
• Develop and maintain engineering processes, standards, and technical documentation.

Skills

SolidWorks CAD

SolidWorks PDM

3D modeling

Additive manufacturing

Team leadership

Mentoring

System integration

Uncrewed aircraft systems

Background check eligibility

Education

Bachelor's degree in Mechanical Engineering or related

Tools

SolidWorks CAD

SolidWorks PDM

3D printing

Job description

COLSA Corporation is seeking a Lead Hardware Design Engineer with small Uncrewed Aircraft Systems (sUAS) experience to provide technical leadership to our design engineering team. This position will lead the design, development, integration, testing, and sustainment of hardware systems supporting sUAS platforms while guiding engineers and technicians throughout the product development process. The selected candidate will work across the full product lifecycle, from concept development and prototyping through manufacturing, system integration, testing, field support, and sustainment.

Principal Duties and Responsibilities:

• Design, develop, and support hardware solutions for small Uncrewed Aircraft Systems (sUAS), including airframes and related components.
• Provide technical guidance and work leadership to junior design engineers and engineering technicians throughout the full production lifecycle.
• Create and maintain 3D models, assemblies, engineering drawings, and manufacturing documentation.
• Manage engineering documentation, revisions, and product configurations using SolidWorks PDM.
• Develop and build prototype hardware using 3D printing and other rapid prototyping methods.
• Evaluate hardware designs to ensure they meet performance, reliability, manufacturability, and cost objectives.
• Support hardware integration, assembly, testing, and validation throughout the development lifecycle.
• Develop and execute hardware test plans, document results, and recommend design improvements based on test findings.
• Collaborate with electrical, software, systems, manufacturing, and test engineers to support successful system integration and product development.
• Prepare engineering documentation, including technical reports, work instructions, and test procedures.
• Apply engineering principles to identify, troubleshoot, and resolve technical challenges while balancing performance, schedule, cost, and mission requirements.
• Participate in design reviews, technical meetings, and customer briefings.
• Develop and maintain engineering processes, standards, and technical documentation.

At COLSA, people are our most valuable resource and centered at our core value. We invite you to unite your talents with opportunity and be a part of our “Family of Professionals!” Learn about our employee-centric culture and benefits here: https://www.colsa.com/culture_benefits

Required Experience

• Bachelor’s degree in Mechanical Engineering, Hardware Engineering, Aerospace Engineering, Electrical Engineering, or a related technical discipline, or equivalent experience
• Minimum of 10-16 years of related experience
• Demonstrated expertise with SolidWorks CAD and SolidWorks PDM
• Hands‑on experience with 3D modeling, additive manufacturing, including 3D printing, rapid prototyping, and design
• Demonstrated ability to evaluate and balance competing system‑level constraints during the design, integration, and testing of uncrewed systems to meet customer needs
• Proven ability to lead and mentor multidisciplinary engineering teams in fast‑paced uncrewed systems design, testing, and field environments
• Experience overseeing multiple complete product development lifecycles for an uncrewed aerial system, from concept through completion
• U.S. Citizenship required; selected candidate must successfully complete a criminal background check prior to the start date

Applicant selected will be subject to a government security investigation and must meet eligibility requirements for access to classified information. COLSA Corporation is an Equal Opportunity Employer, Minorities/Females/Veterans/Disabled. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, or national origin.

Salary Type

Annually

The salary range, if referenced, represents a good faith estimate. COLSA considers various factors when determining base salary offers, but not limited to, location, the role, function and associated responsibilities, a candidate’s particular combination of education, knowledge, skills, competencies, and experience, as well as contract‑specific affordability and organizational requirements.

COLSA offers a comprehensive and customizeable benefits program which includes:

• Medical
• Dental
• Vision
• Life Insurance
• Short-Term Disability
• Long-Term Disability
• Accidental Death & Dismemberment
• Supplemental Income Protection Programs
• 401(k) with company match
• Flexible Spending Accounts
• Employee Assistance Program
• Education & Certification Reimbursement
• Employee Discount Program
• Paid Time Off
• Holidays

This position will be posted for a minimum of 3 business days. If a candidate has not been selected at that time, it will continue to be posted until a suitable candidate is selected or the position is closed.