Principal Hardware-in-the-Loop Engineer

CHAOS Industries•Hawthorne, CA

1d•Onsite

About The Position

CHAOS Industries is redefining modern defense with a multi-product portfolio that gives the ultimate advantage—domain dominance. The company's products are powered by Coherent Distributed Networks (CDN™), empowering warfighters, commercial air operators, and border protection teams to act faster, adapt rapidly, and stay ahead of evolving threats. CHAOS Industries was founded in 2022 and has raised a total of $1 billion in funding from leading investors, including 8VC, Accel, and Valor Equity Partners. The company is headquartered in Los Angeles, with offices in Washington, D.C., San Francisco, San Diego, Seattle, and London. For more information, please visit www.chaosinc.com. Role Overview: CHAOS is seeking a Principal Hardware-in-the-Loop (HIL) Engineer to lead the architecture, development, and deployment of advanced HIL simulation environments supporting high-reliability effector platforms. This role is responsible for defining scalable, high-fidelity validation frameworks that enable full system integration testing across multiple programs—bridging software, autonomy, and flight hardware. This position spans the full lifecycle of HIL development, from early requirements shaping and simulation architecture through hardware/software integration, automated test development, system validation, and transition to flight test. The ideal candidate is a highly experienced, hands-on engineer who can lead complex HIL efforts, guide other engineers, and ensure consistent, high-quality validation approaches across programs. This is a full-time, on-site position in Hawthorne, CA.

Requirements

Bachelor's degree in Engineering, Computer Science, or a related field
10+ 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, debugging and root cause analysis skills across hardware, software, and simulation domains
Demonstrated ability to lead technical efforts and guide engineers through complex integration and troubleshooting challenges
Ability to obtain and maintain a U.S. security clearance

Nice To Haves

Advanced degree (MS or PhD) in Engineering or related field
Experience with ROS or ROS 2 for simulation and integration testing
Strong background in flight dynamics, control systems, or GNC model development (MATLAB/Simulink or similar)
Experience correlating simulation environments with real-world flight test data
Familiarity with FPGA-based simulation, embedded Linux systems, or real-time computing architectures
Experience with RF systems, GPS signal simulation, or sensor fusion validation
Experience establishing reusable simulation frameworks or model libraries across programs
Exposure to flight test operations and transitioning systems from HIL to field testing
FAA Part 107 certification or equivalent UAV operational credentials

Responsibilities

Lead the architecture, design, and development of HIL test benches for full effector system integration, including flight controllers, ESCs, sensors, and ground control systems
Define HIL strategy, fidelity requirements, and validation approaches to ensure comprehensive system-level test coverage prior to flight
Establish reusable approaches for HIL system design, model integration, and test automation across programs
Architect and integrate high-fidelity simulation models (flight dynamics, actuator, and sensor models) that accurately replicate real-world behavior
Lead integration of hardware components into HIL systems, including flight computers, ESCs, communication links, sensors, and power systems
Drive development of automated test frameworks, regression infrastructure, and CI/CD integration for continuous validation of software and firmware
Guide debugging and root cause analysis of complex hardware-software interactions using HIL data, logs, and telemetry
Collaborate with GNC, software, and systems engineering teams to define verification strategies, test plans, and acceptance criteria across programs
Own, 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