UAS Fabricator

Systems Planning and Analysis; Bowie (MD); On-site; USD 40,000 - 60,000; Full time

Job summary

Systems Planning and Analysis, Inc. (SPA) is seeking an entry-level UAS Builder to work full-time on-site in Bowie, MD. You will build Group 1–3 UAS from airframe to wiring and avionics, under supervision of flight crews and engineers.

Prior piloting experience is not required. Responsibilities include fabricating structures, wiring harnesses, and integrating flight control systems, calibrating sensors, and testing aircraft performance.

Qualifications

• Two years of hands-on RC aircraft/UAS build experience or equivalent.
• Two years of UAS maintenance or aviation electronics experience.
• Ability to read engineering drawings, wiring diagrams, and parts lists.
• Proficiency with hand and power tools, and accurate assembly.
• Experience with carbon fiber and fiberglass layups and repair.

Responsibilities

• Build, assemble, and integrate fixed-wing and multirotor UAS using drawings and wiring diagrams.
• Fabricate and repair aircraft structures with composite materials and 3D-printed parts.
• Assemble wiring harnesses and power distribution systems; solder and crimp as needed.
• Install battery systems with safe handling, charging, and storage practices.
• Install and integrate flight control systems, GPS, telemetry, RC, and payload subsystems.
• Configure ArduPilot and PX4 firmware; calibrate sensors and ESCs.
• Test aircraft systems including motor thrust, current draw, controls, and failsafes.
• Document test results and support flight tests with crew.
• Inspect, troubleshoot, and repair airframes after incidents; review logs.

Skills

UAS assembly

Soldering

Engineering drawings

Hand tools

Power tools

Composite fabrication

Attention to detail

Physical stamina

RC aircraft experience

Verbal/written communication

Education

High school diploma or GED

UAS/aviation maintenance program

FAA Part 107 Remote Pilot Certificate

IPC certification / other avionics certs

Tools

SolidWorks

Fusion 360

3D printing

Calipers

Multimeters

Torque drivers

Job description

Overview

Systems Planning and Analysis, Inc. (SPA) delivers high-impact, technical solutions to complex national security issues. With over 50 years of business expertise and consistent growth,we are known for continuous innovation for our government customers, in both the US and abroad. Our exceptionally talented team is highly collaborative in spirit and practice, producingResults that Matter. Come work with the best! We offer opportunity, unique challenges, and clear-sighted commitment to the mission. SPA: Objective. Responsive. Trusted.

The Strategic Division (SD) supports high-reliability organizations including Navy Strategic Systems Programs (SSP), Air Force Nuclear Weapons Center, and the Department of Energy (DOE), among others. Our support across our client base is expanding rapidly and encompasses important services, such as data analytics and visualization, threat analysis, risk management, modeling and simulation, cost estimating, earned value management, program management, system engineering, independent evaluation, and High Consequence Event prevention.

The Surety Programs Group (SPG) supports government and private sector management of complex safety, security, and reliability programs for high consequence operations. SPG delivers industry-leading, innovative, and value-added services such as data analytics and visualization, threat analysis, risk management, modeling and simulation, program management, system engineering, independent evaluation, and High Consequence Event prevention to help our clients understand and mitigate mission risks spanning physical, cyber, and human domains.

SPA has an immediate need for a UAS Builder to work full time, on-site in Bowie, MD. This is an entry-level, hands‑on build position. You will manually build Group 1 through Group 3 fixed‑wing and multirotor unmanned aircraft, from bare airframe structure through wiring, propulsion, avionics integration, and ground test, working alongside our flight crews and engineers. Prior UAS piloting experience is not required.

Responsibilities

The candidate will:

• Build, assemble, and integrate Group 1, 2, and 3 fixed‑wing and multirotor unmanned aircraft systems (UAS) using engineering drawings, wiring diagrams, parts lists, and work instructions.
• Fabricate, modify, and repair aircraft structures using carbon fiber, fiberglass, wood, foam, adhesives, vacuum bagging, film covering, and 3D‑printed components.
• Build wiring harnesses and power distribution systems by stripping, crimping, soldering, and connecting wires and electrical components.
• Assemble and install battery systems while following safe procedures for handling, charging, storing, transporting, and disposing of batteries.
• Install and integrate flight control systems, GPS/GNSS receivers, telemetry radios, RC systems, video equipment, servos, actuators, and payload systems.
• Configure ArduPilot and PX4 firmware and calibrate sensors, radios, electronic speed controllers (ESCs), and failsafe systems.
• Test aircraft systems by performing electrical and functional checks, measuring motor thrust and current draw, verifying control surfaces and center of gravity, and testing radio range and failsafe functions.
• Document test results and support flight crews during test flights.
• Inspect, troubleshoot, and repair aircraft following hard landings or other incidents. This includes identifying problems with airframes, wiring, connectors, and flight systems and reviewing flight logs when needed.
• Maintain accurate build records, configuration data, serial numbers, inspection reports, and nonconformance documentation.
• Support inventory management, parts preparation, and tool control while assisting with customer support, aircraft fabrication, maintenance, servicing, and repairs.
• Maintain a clean, organized, and safe workspace free of foreign object debris (FOD).

Qualifications

Required Qualifications:

• Citizenship and education: U.S. citizen with a high school diploma or GED and the ability to obtain and maintain a security clearance if required.
• Relevant experience or education: Meet at least one of the following:
  • Two years of hands‑on experience building, assembling, repairing, or maintaining RC aircraft or UAS.
  • Two years of military or contractor UAS maintenance experience.
  • Two years of aviation, avionics, or electromechanical assembly experience.
  • Completion of an accredited UAS, aviation maintenance, or electronics technical program.
  • Engineering education or relevant academic experience, including laboratory work, design‑and‑build projects, or competitions such as AIAA Design/Build/Fly or SAE Aero Design.
  • A verifiable portfolio of scratch‑built or kit‑built RC aircraft.
  • An equivalent combination of education and experience.
• Electrical and assembly skills: Proficiency in hand soldering, including high‑current motor and battery connections, and building wire harnesses to established standards.
• Technical skills: Ability to read engineering drawings, wiring diagrams, parts lists, and work instructions. Experience using hand tools, power tools, calipers, torque drivers, and multimeters.
• Composite fabrication: Working knowledge of carbon fiber and fiberglass fabrication and repair, including layup, vacuum bagging, bonding, trimming, and finishing. Ability to handle resins, solvents, and adhesives safely.
• Workmanship and teamwork: Strong attention to detail, consistent workmanship, and the ability to follow instructions, complete repetitive tasks accurately and on schedule, and work under the direction of project leads.
• Physical and work requirements: Ability to lift more than 35 pounds and work outdoors in varying environmental conditions. Must work full-time, on‑site in Bowie, MD. Monday through Friday or as required by the contract. Must be willing to travel, including potentially internationally, and hold a current passport.

Desired Qualifications:

• Certifications and Education: FAA Part 107 Remote Pilot Certificate; associate degree or higher or technical certificate in aviation maintenance, UAS technology, or electronics; IPC certification(J-STD-001, IPC-A-610, or IPC/WHMA-A-620); FAA Airframe and Powerplant (A&P) certificate or enrollment in an approved program; current DOT lithium battery shipping training; and/or an active DoD security clearance.
• UAS and Flight Systems: Experience configuring ArduPilot or PX4, tuning flight parameters,reviewing flight logs, and building or maintaining Group 2 and Group 3 UAS, including larger airframes.
• Fabrication and Specialized Systems: CAD proficiency with SolidWorks, Fusion 360, orsimilar software; FDM 3D printing with engineering-grade materials; and experience building, installing, or maintaining small turbine engines and turbine‑powered model aircraft.