UAS Design Engineer

Company Overview

By Light Professional IT Services LLC readies warfighters and federal agencies with technology and systems engineered to connect, protect, and prepare individuals and teams for whatever comes next. Headquartered in McLean, VA, By Light supports defense, civilian, and commercial IT customers worldwide.

Position Overview

The UAS Design Engineering Lead provides technical leadership and subject matter expertise in the design, rapid prototyping, integration, and testing of Unmanned Aircraft Systems (UAS) for government programs. This role ensures all engineering efforts-particularly for Group 1 and Group 2 UAS platforms-are aligned with contractual requirements, industry standards, and program objectives, while guiding a multidisciplinary team through all phases of the UAS lifecycle.

This is not a remote position; the selected candidate will be required to work onsite in Port Orange, FL.

Responsibilities

• Technical Leadership: Direct and oversee the UAS design engineering team, ensuring technical excellence and innovation, with a focus on Group 1 and Group 2 UAS platforms.
• Requirements Analysis: Analyze, interpret, and decompose customer and stakeholder requirements into actionable engineering specifications, particularly for Group 1 and 2 unmanned aerial systems.
• Rapid Design & Prototyping: Quickly design, prototype, and iterate new UAS solutions based on evolving customer requirements and timelines, with demonstrated expertise in Group 1 and 2 UAS development.
• 3D Concept Development: Utilize Autodesk Inventor and/or SolidWorks for advanced 3D modeling to develop, iterate, and refine UAS concepts, assemblies, and components from initial concept through final design.
• DFM/DFA Integration: Apply Design for Manufacturability (DFM) and Design for Assembly (DFA) methodologies to ensure optimized production and assembly processes, reducing cost and complexity while improving quality and reliability.
• Systems Architecture: Lead the development and validation of UAS architectures, subsystems, and interfaces.
• Integration & Testing: Oversee system integration, test planning, execution, and design verification/validation efforts for Group 1 and 2 UAS.
• Risk Management: Identify technical risks; develop and implement mitigation strategies throughout the project lifecycle.
• Compliance & Standards: Ensure all designs adhere to relevant regulatory, military, and industry standards (e.g., FAA, DoD, MIL-STD), specifically as they apply to Group 1 and 2 UAS categories.
• Documentation: Prepare and review technical documentation, design artifacts, and compliance reports for stakeholders.
• Stakeholder Engagement: Serve as primary technical liaison with program management, customers, and suppliers.
• Team Development: Mentor, train, and support the continuous development of engineering staff.

Required Experience/Qualifications

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Electrical Engineering, or a related discipline. Master's degree preferred.

• Minimum of 5 years of progressively responsible experience in aerospace or defense engineering, including UAS design and development.

• Demonstrated expertise in the design, prototyping, integration, and testing of Group 1 and Group 2 UAS platforms, including knowledge of applicable DoD and FAA categorization and requirements.

• Proven experience applying Design for Manufacturability (DFM) and Design for Assembly (DFA) methodologies to optimize product designs for efficient manufacturing and assembly.

• Proven ability to develop and refine engineering concepts and solutions utilizing Autodesk Inventor and/or SolidWorks for advanced 3D modeling.

• In depth knowledge and expertise in all aspects of UAS systems software: drone platform operating systems, component firmware, base station software, TAK software. Ability to load, configure and test SW as required on drones and drone system components. Ability to identify and relate technical software requirements to with internal and external software developers.

• Software experience with UAS control and integration software including EdgeTX, MAVLink, ArduPilot, TAK APIs, Betaflight, etc.

• Demonstrated expertise in systems engineering principles, product lifecycle management, and multidisciplinary team leadership.

• Strong ability to rapidly design, prototype, and iterate new solutions in response to dynamic customer requirements.

• Deep knowledge of relevant regulations and standards (e.g., FAA Part 107, MIL-STD-810, DO-178C, DO-254).

• Flexibility and agility to adjust schedules to meet rapidly evolving customer requirements.

• Lead and manage an in house rapid prototyping facility (ie "maker shop") and staff.

• Proven track record in delivering complex aerospace or UAS projects on time and within budget.

• Strong communication, interpersonal, and presentation skills.

• Ability to work in a fast-paced, dynamic, and collaborative team environment.

• Willingness to travel as required to support program objectives or customer engagements.

Preferred Experience/Qualifications

• Advanced degree (MS/PhD) in engineering or related field.
• Demonstrated experience with rapid prototyping resources and processes focused on Group 1 and 2 UAVs.
• Ability to write code, firmware as required.
• FAA Part 107 Certification

Special Requirements/Security Clearance

• Ability to obtain and maintain a Secret security clearance as required by contract or program needs.