HIL Engineer

Role Overview 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 El Segundo, CA.

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

Minimum 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

Preferred Requirements 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

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

$130k-190k

The stated compensation range reflects only the targeted base compensation range and excludes additional earnings such as bonus, equity, and 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.

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