UAS Design and Integration Engineer

Johns Hopkins Applied Physics Laboratory; Laurel (MD); On-site; USD 100,000 - 245,000; Full time

Job summary

Johns Hopkins Applied Physics Laboratory seeks an experienced UAS Design and Integration Engineer to own prototypes from concept to delivery. You will lead hands-on assembly, integration of platforms, sensors, and payloads, and balance performance with cost and field repairability.

You will translate mission needs into practical, low-cost solutions while coordinating across mechanical, electrical, software, and autonomy teams.

Qualifications

• Bachelor's degree in Aerospace, Mechanical, Electrical, or related engineering field.
• Experience designing, building, integrating and testing custom UAS or similar hardware deployed for users.
• Experience owning technical solutions through build, test, and iterative improvement.
• Experience designing and troubleshooting complex mechanical and electrical aerospace or prototype systems.
• Proficiency with modern UAS autopilot systems (e.g., PX4, ArduPilot) and ground control software.
• Strong understanding of UAS subsystems: avionics, propulsion, GNC, electricals, payloads, interfaces.
• Effective cross-disciplinary communication and decision-making to support integrated system performance.
• Hands-on in labs, machine shops, and field environments; willing to move between design, fabrication, integration, testing and failure investigation.

Responsibilities

• Own design and integration of UAS prototypes from concept through build, testing, failure analysis, redesign and delivery to test teams.
• Lead hands-on assembly and integration of UAS platforms: fabrication, wiring, propulsion, sensors, and payloads.
• Translate mission needs into practical, low-cost vehicle and system solutions balancing performance, mass, power, cost, and maintainability.
• Collaborate across mechanical, electrical, software, autonomy, test and operations to ensure cohesive system performance.
• Design and integrate flight control systems, autopilot configuration, sensor calibration, and GNC tuning.
• Plan and execute lab, ground and flight testing; analyze results; drive iterative design improvements.
• Communicate risks and issues early and drive corrective actions for next build or test.
• Produce as-built configurations, test procedures, checklists, and lessons learned.

Skills

Hands-on engineering

System integration

Cross-disciplinary collaboration

Strong communication

Education

Bachelor's degree in Aerospace Engineering

Tools

PX4

ArduPilot

SolidWorks

Soldering

Job description

Description

Are you interested in working on multidisciplinary teams that transform rough ideas into operational uncrewed air systems through design, build, integration, testing, failure analysis, and rapid iteration? Are you interested in applying hands-on engineering skills to develop low-cost autonomous systems and defense mission capabilities that must perform reliably for real users in realistic operational environments?

If so, we're looking for someone like you to join our team at APL.

Who are we?

We are the Intelligent Combat Systems Group, and our mission is to ensure our Nation maintains an operational advantage on the future battlefield through advances in artificial intelligence, autonomy, human-machine teaming, and novel uncrewed aircraft design and testing.

We believe the future battlefield will be shaped by intelligent autonomous systems capable of operating with machine precision at machine speed. Our teams bring together engineers, technicians, operators, and analysts to rapidly move from concepts and CAD models to hardware, ground testing, flight testing, lessons learned, redesign, and delivery.

Our work has contributed to nationally recognized programs including DARPA Air Combat Evolution (ACE), AFRL Golden Horde, and Air Force Skyborg, demonstrating our impact in advancing autonomous air systems.

We are seeking highly motivated engineers who enjoy building and integrating complete systems to solve urgent real-world problems. Our team is entrepreneurial and multidisciplinary. We value working prototypes, disciplined testing, candid communication, collaboration, and teammates who stay engaged until the system performs in the hands of the user. We especially value engineers who take ownership of failures, learn from them quickly, and improve the complete system rather than optimizing only their individual component.

As a UAS Design And Integration Engineer, You Will

• Own the design and integration of UAS prototypes from concept development and trade studies through build, laboratory checkout, ground and flight testing, failure investigation, redesign, and delivery to test teams and end users.
• Lead and participate in the hands-on assembly and integration of UAS platforms, including composite fabrication and repair, component installation, custom wiring harness fabrication, soldering, propulsion systems, sensors, and payload integration.
• Translate mission needs and operational constraints into practical, low-cost vehicle, payload, avionics, propulsion, and ground support solutions while balancing performance, mass, power, cost, schedule, reliability, safety, maintainability, and field repairability.
• Collaborate across mechanical, electrical, software, autonomy, test, and operations teams to ensure design decisions support the performance of the complete integrated system rather than an isolated subsystem.
• Design and integrate flight control systems, including autopilot configuration, sensor calibration, and GNC tuning to optimize flight performance across conventional and nontraditional UAS configurations.
• Plan, coordinate, and execute laboratory, ground, and flight testing; analyze results; identify root causes; and drive iterative design improvements based on test data and operational feedback.
• Communicate technical risks, design issues, integration challenges, and schedule impacts early, and help drive corrective actions through the next build, test, or field event.
• Produce practical documentation that enables teammates to build, test, operate, maintain, repair, and improve the system, including as-built configurations, test procedures, checklists, and lessons learned.

Qualifications

You meet our minimum qualifications for the job if you:

• Have a Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Electrical Engineering, or a related engineering field.
• Have demonstrated professional, military, or substantial hands-on project experience designing, building, integrating, and testing custom uncrewed aerial systems, aircraft, robotics, or other complex hardware systems deployed for users, operators, customers, or mission demonstrations.
• Have experience owning technical solutions through build, testing, troubleshooting, and iterative improvement—not solely analysis or design handoff.
• Have experience designing, integrating, operating, and troubleshooting complex mechanical and electrical aerospace, robotic, or prototype systems.
• Are proficient with modern UAS autopilot systems (e.g., PX4, ArduPilot) and their associated ground control software.
• Have a strong understanding of UAS subsystems, including avionics, propulsion, GNC, electrical systems, payload integration, and hardware interfaces.
• Communicate effectively across mechanical, electrical, software, test, and operations disciplines, and make design decisions that support the performance of the integrated system.
• Enjoy working hands-on in laboratories, machine shops, and field environments, and are comfortable moving between engineering design, prototype fabrication, system integration, testing, and failure investigation.
• Hold an active Secret security clearance and can ultimately obtain a TS/SCI level clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship.

You’ll go above and beyond our minimum requirements if you

• Have 3+ years of relevant professional experience with integrated flight systems, UAS development, or prototype hardware.
• Have led or made significant technical contributions to multiple prototype build-test-learn cycles and can describe key failures, corrective actions, and resulting improvements.
• Hold a current FAA Part 107 Remote Pilot Certificate and have significant flight experience across multiple UAS platforms.
• Possess extensive experience integrating avionics, including the selection, installation, checkout, and troubleshooting of sensors, flight computers, communications equipment, and other flight hardware.
• Demonstrate strong experience tuning flight control systems (GNC), particularly for unconventional or VTOL aircraft.
• Are proficient with CAD software (e.g., SolidWorks) for component design, packaging, integration planning, and rapid design iteration.
• Have experience designing systems for low-cost manufacturing, rapid repair, field modification, maintainability, or low-volume production.
• Have supported field testing or flight operations where hardware readiness, logistics, schedule pressure, operators, and evolving prototype hardware had to be managed simultaneously.
• Have experience developing CONEMPs (Concepts of Employment) and mission system architectures for UAS.
• Hold an active TS/SCI security clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship.

About Us

The Johns Hopkins University Applied Physics Laboratory (APL) brings world-class expertise to our nation’s most critical defense, security, space and science challenges. While we are dedicated to solving complex challenges and pioneering new technologies, what makes us truly outstanding is our culture. We offer a vibrant, welcoming atmosphere where you can bring your authentic self to work, continue to grow, and build strong connections with inspiring teammates.

Why Work at APL?

At APL, we celebrate our differences of perspectives and encourage creativity and bold, new ideas. Our employees enjoy generous benefits, including a robust education assistance program, unparalleled retirement contributions, and a healthy work/life balance. APL’s campus is located in the Baltimore-Washington metro area. Learn more about our career opportunities at https://www.jhuapl.edu/careers.

All qualified applicants will receive consideration for employment without regard to race, creed, color, religion, sex, gender identity or expression, sexual orientation, national origin, age, physical or mental disability, genetic information, veteran status, occupation, marital or familial status, political opinion, personal appearance, or any other characteristic protected by applicable law. APL is committed to providing reasonable accommodation to individuals of all abilities, including those with disabilities. If you require a reasonable accommodation to participate in any part of the hiring process, please contact [e-mail].

The referenced pay range is based on JHU APL’s good faith belief at the time of posting. Actual compensation may vary based on factors such as geographic location, work experience, market conditions, education/training and skill level with consideration for internal parity. For salaried employees scheduled to work less than 40 hours per week, annual salary will be prorated based on the number of hours worked. APL may offer bonuses or other forms of compensation per internal policy and/or contractual designation. Additional compensation may be provided in the form of a sign-on bonus, relocation benefits, locality allowance or discretionary payments for exceptional performance. APL provides eligible staff with a comprehensive benefits package including retirement plans, paid time off, medical, dental, vision, life insurance, short-term disability, long-term disability, flexible spending accounts, education assistance, and training and development. Applications are accepted on a rolling basis.

Minimum Rate

$100,000 Annually

Maximum Rate

$245,000 Annually