Hardware-in-the-Loop Engineer

CHAOS Industries•Hawthorne, CA

1d•Onsite

About The Position

CHAOS is seeking a skilled Hardware-in-the-Loop (HIL) Engineer to join our hardware engineering team. In this role, you will design, build, and maintain HIL simulation environments that enable full system integration testing of our Effector platforms — bridging the gap between software development and flight hardware. You will work closely with GNC, software, and systems engineers to ensure our vehicles are thoroughly validated before ever leaving the ground. The ideal candidate has hands-on experience building and operating HIL or SIL simulation environments for embedded or autonomous systems. This is a full-time, on-site position in Hawthorne, CA.

Requirements

Bachelor's degree in Engineering, Computer Science, or a related field.
3+ years of experience in hardware-in-the-loop testing, embedded systems integration, or a closely related discipline
Hands-on experience building and operating HIL or SIL simulation environments for embedded or autonomous systems
Proficiency in real-time simulation platforms (e.g., dSPACE, NI VeriStand, or similar)
Strong programming skills in Python and/or C/C++ for test automation and system scripting
Familiarity with flight controller software such as PX4, ArduPilot, or equivalent
Experience with communication protocols common in drone systems (MAVLink, CAN, UART, SPI, I2C)
Solid understanding of effector system architecture, including propulsion, navigation, and control loops
Experience with version control systems and CI/CD pipelines for automated testing
Strong analytical and troubleshooting skills across hardware and software domains
Ability to obtain and maintain a U.S. security clearance

Nice To Haves

Master’s degree in Engineering
Experience with ROS or ROS 2 for simulation and integration testing
Familiarity with MATLAB/Simulink for flight dynamics or control system modeling
Exposure to flight test operations and transitioning systems from HIL to field testing
Experience with FPGA firmware development or embedded Linux environments
Knowledge of RF systems, GPS signal simulation, or sensor fusion techniques
FAA Part 107 certification or equivalent UAV operational credentials

Responsibilities

Design and develop HIL test benches for full effector system integration, including flight controllers, ESCs, sensors, and ground control systems
Integrate high-fidelity simulation models (flight dynamics, actuator, and sensor models) that accurately replicate real-world behavior
Integrate hardware components - including autopilot boards, communication links, power systems, and peripherals - into HIL systems
Develop automated test suites and regression frameworks to validate software and firmware changes against HIL environments
Collaborate with software and integration/test engineers to define test plans and acceptance criteria for new features and hardware releases
Debug complex hardware-software interactions by analyzing HIL test data, logs, and telemetry
Maintain and improve test infrastructure, including simulation software, real-time targets, and data acquisition systems
Document test methodologies, procedures, and results clearly for cross-functional team use
Support transition of HIL-validated systems to integration and flight test phases