Principal Hardware-in-the-Loop Engineer

• 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
• border protection teams to act faster, adapt rapidly
• 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
• Valor Equity Partners. The company is headquartered in Los Angeles, with offices in Washington, D.C., San Francisco, San Diego, Seattle
• 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
• 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
• 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
• transition to flight test. The ideal candidate is a highly experienced, hands-on engineer who can lead complex HIL efforts, guide other engineers
• ensure consistent, high-quality validation approaches across programs.
• This is a full-time, on-site position in El Segundo, CA

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
• Minimum 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
• Preferred Requirements:
• 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
• Why CHAOS?
• Health Benefits: Medical, dental, and vision benefits 100% paid for by the company
• Additional benefits : 401k (+ 50% company match up to 6% of pay), FSA, HSA, life insurance, and more
• Our Perks: Free daily lunch, ‘No meeting Fridays’, unlimited PTO, casual dress code
• Compensation Components: Competitive base salaries, generous pre-IPO stock option grants, relocation assistance, and (coming soon!) annual bonuses
• Team Growth: 250 employees and counting across 5 global offices
• $170k-240k
• The stated compensation range reflects only the targeted base compensation range and excludes additional earnings such as bonus, equity
• benefits. If your compensation requirements fall outside of the range, we still encourage you to apply. The salary range for this role is an estimate based on a range of compensation factors, inclusive of base salary only. Actual salary offer may vary based on (but not limited to) work experience, education and/or training, critical skills, and/or business considerations.
• Recruiting Agencies: CHAOS Industries does not accept unsolicited resumes or outreach. Unsolicited submissions will not be reviewed or compensated.
• #LI-onsite