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, 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 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 c…