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Unmanned Aerial System (UAS) Development, Integration & Test Engineer

Skyline Nav AI, Inc.
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We are seeking a motivated UAS Integration & Test Engineer to own the full lifecycle of bringing a proprietary Unmanned Aerial System (UAS) platform from initial design files to commercial flight readiness. Working with fixed-wing, VTOL aircraft and quadcopter architectures, you will adapt airframe designs, optimize production workflows, integrate avionics, and manage flight-testing operations.

Key Responsibilities

  • CAD & Product Optimization: Modify existing airframe design files in CAD (Fusion 360, SolidWorks, etc.) to adapt the platform for commercial requirements, payload integration, structural durability, and efficient assembly.
  • Additive Manufacturing & Fleet Production: Slice, optimize, and manage the production of airframe components using high-performance materials (LW-PLA, PETG, and Polycarbonate)—balancing structural integrity and weight targets through internal 3D printers or external production partners.
  • Mechanical & Systems Assembly: Perform airframe bonding, carbon fiber spar installation, control surface linkage setup, and hardware integration. Wire onboard avionics including flight controllers, ESCs, GPS/compass units, telemetry systems, and power distribution.
  • Autopilot & Software Setup: Flash, configure, and calibrate ArduPilot (ArduPlane / Quadplane) flight control stacks. Establish control throws, fail-safe protocols, sensor calibrations, and autonomous mission parameters.
  • Flight Testing & System Validation: Execute bench testing, pre-flight checks, and flight-test programs. Conduct trim flights, tuning sessions, and validate commercial performance metrics including range, payload endurance, and autonomous landing behavior.

Required Qualifications

  • Bachelor’s degree in Aerospace, Mechanical, Electrical, Mechatronics, or Systems Engineering.
  • Practical experience with FDM 3D printing (slicing profiles, bed adhesion, material properties).
  • Hands-on experience assembling, wiring, and configuring fixed-wing or multirotor UAV systems.
  • Familiarity with the ArduPilot ecosystem and ground control software (Mission Planner or QGroundControl).
  • Proficiency with basic shop tools, soldering, wiring harness fabrication, and battery systems (LiPo/Li-Ion).

Preferred Qualifications

  • Experience with VTOL or Quadplane airframe configurations and tuning logic.
  • Active FAA Part 107 Remote Pilot Certification.
  • CAD surface modeling skills to adapt airframes for custom internal compartments or external sensor mounts