Rapid Prototyping Engineer – Drones & Unmanned Systems

📍 Job Overview

Job Title: Rapid Prototyping Engineer – Drones & Unmanned Systems

Company: HavocAI

Location: San Diego, California, United States

Job Type: Full-Time

Category: Engineering - Hardware Development / Robotics Operations

Date Posted: September 2, 2026

Experience Level: Mid-Level (3+ years)

Remote Status: Hybrid

🚀 Role Summary

• Lead the technical maturation of advanced unmanned aircraft systems (UAS) from prototype to fieldable, Low-Rate Initial Production (LRIP) platforms.

• Focus on hands-on hardware development, transforming early concepts into functional prototypes through rapid iteration and design.

• Integrate complex mechanical and electrical systems, troubleshoot vehicle performance, and implement fast design changes based on test results.

• Collaborate closely with a team of exceptional engineers to solve challenging problems in demanding environments, shaping the future of autonomous systems.

• Drive innovation in all-domain collaborative autonomy, contributing to software-defined hardware solutions for military and commercial applications.

📝 Enhancement Note: While the role title is "Rapid Prototyping Engineer," the core responsibilities and required qualifications strongly align with a hardware-focused engineering role within a GTM context, specifically supporting product development and early-stage market readiness for advanced autonomous systems. The emphasis on transitioning from prototype to LRIP signifies a connection to Go-to-Market (GTM) product lifecycle stages.

📈 Primary Responsibilities

• Drive the rapid transformation of drone concepts and requirements into fully functional prototype unmanned aircraft systems (UAS).

• Design, modify, and optimize airframes, mechanisms, mounting brackets, enclosures, and critical payload interfaces for prototype vehicles.

• Assemble and build prototype unmanned aircraft and their subsystems, ensuring seamless integration of all components.

• Integrate essential electromechanical systems including motors, propulsion units, batteries, avionics, sensors, compute hardware, communication modules, and various payloads.

• Produce precise quick-turn CAD designs and comprehensive engineering drawings to support prototype fabrication and assembly.

• Utilize a variety of fabrication methods such as additive manufacturing (3D printing), CNC machining, sheet metal work, and composite material processing to create prototype parts.

• Engage in hands-on fabrication, assembly, rework, and modification of prototype hardware to meet evolving design specifications.

• Develop and construct specialized test fixtures and experimental setups to validate system performance and identify potential issues.

• Provide direct support for bench testing, ground testing, environmental testing, and critical flight testing phases of prototype development.

• Diagnose and resolve hardware and integration failures across complex mechanical and electromechanical systems, ensuring operational reliability.

• Implement rapid design iterations and redesign components based on comprehensive test results and performance feedback.

📝 Enhancement Note: The responsibilities highlight a deep dive into the physical product development lifecycle for autonomous systems, directly impacting the readiness and viability of products for potential market entry or further development stages. This role is crucial for the "product engineering" aspect that underpins GTM success.

🎓 Skills & Qualifications

Education: BS in Mechanical Engineering, Aerospace Engineering, Robotics, Mechatronics, or equivalent practical engineering experience.

Experience: 3+ years developing physical hardware systems, with a demonstrated track record in building and testing drones, UAVs, robotics, aircraft, or autonomous systems.

Required Skills:

• Advanced mechanical Computer-Aided Design (CAD) skills for complex component and assembly design.

• Significant hands-on experience in the construction and assembly of electromechanical prototypes.

• Proficiency with multiple manufacturing and fabrication processes, including but not limited to additive manufacturing, CNC machining, and manual fabrication.

• Strong mechanical intuition and proven ability to troubleshoot real-world hardware problems effectively.

• Comfort and proficiency in using common shop tools and performing prototype assembly and modification tasks.

• Experience with system integration, particularly in combining mechanical, electrical, and electronic components.

• Ability to rapidly iterate designs based on testing and feedback loops. Preferred Skills:

• Personal projects or significant experience designing, building, modifying, or operating drones/UAVs.

• Experience with various UAV platforms such as multirotor, VTOL (Vertical Take-Off and Landing), fixed-wing, or hybrid configurations.

• Hands-on experience integrating electric propulsion systems, including motors, Electronic Speed Controllers (ESCs), and battery management.

• Familiarity with integrating key drone components: motors, ESCs, batteries, servos, flight controllers, radios, GPS modules, sensors, and other avionics.

• Experience derived from RC aircraft, drone racing, experimental aircraft building, robotics competitions, or similar hands-on engineering projects.

📝 Enhancement Note: The required qualifications emphasize a blend of theoretical knowledge (degree) and extensive practical, hands-on experience with physical systems, particularly in the drone and robotics domain. The preferred skills suggest a candidate who is not only professionally trained but also deeply engaged in the hobbyist or advanced enthusiast community, indicating a strong passion and intrinsic motivation for the field. This level of practical experience is critical for rapid prototyping and early-stage product development.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Showcase a minimum of 2-3 detailed case studies demonstrating the end-to-end process of taking a physical hardware concept from ideation to a functional prototype.

• Highlight projects involving the design, fabrication, assembly, and testing of electromechanical systems, with a strong emphasis on drones, UAVs, or robotics.

• Include examples of CAD models, engineering drawings, and fabrication outputs (e.g., 3D prints, machined parts) that illustrate design complexity and manufacturing considerations.

• Demonstrate problem-solving skills through documentation of challenges encountered during prototyping and the solutions implemented, focusing on efficiency and effectiveness.

• Quantify results where possible, such as improvements in performance metrics, reduction in weight, or speed of iteration achieved through your prototyping efforts. Process Documentation:

• Provide documentation of your personal or professional process for rapid prototyping, including stages like requirements gathering, conceptualization, design, material selection, fabrication, assembly, integration, and testing.

• Illustrate your approach to iterative design and how feedback loops from testing are incorporated into subsequent design iterations.

• Detail your experience with specific manufacturing processes (e.g., 3D printing parameters, CNC toolpaths, composite layup procedures) and how you optimize them for rapid prototype development.

• Explain your methodology for troubleshooting electromechanical systems, including diagnostic steps and root cause analysis techniques.

📝 Enhancement Note: For a role centered on rapid prototyping and hardware development, a tangible portfolio is paramount. It serves as direct evidence of a candidate's ability to execute on complex engineering tasks. The expectation is not just to list skills, but to visually and descriptively demonstrate the application of those skills in real-world projects, showcasing the entire product development lifecycle from concept to functional prototype.

💵 Compensation & Benefits

Salary Range: $150,000 - $180,000 USD per year.

Benefits:

• Comprehensive Health, Dental, and Vision Insurance: 100% employer-paid for employees and their families.

• Life Insurance: Employer-paid coverage.

• 401k Program: With employer matching contributions.

• Unlimited Paid Time Off (PTO): With a mandatory minimum of 2 weeks taken annually.

• Equity Package: Opportunity to own a stake in the company's growth.

• Work/Home Office Stipend: To enhance remote or hybrid work setups.

• Global Entry: Expedited customs processing for international travel.

• Paid Parental Leave: 16 weeks of paid leave for new parents.

• Monthly Health and Wellness Stipend: For personal well-being activities.

Working Hours: 40 hours per week, with flexibility inherent in a hybrid work arrangement.

📝 Enhancement Note: The provided salary range is competitive for a mid-level engineering role in a high-cost-of-living area like San Diego, especially within the defense technology sector. The benefits package is exceptionally generous, indicating a strong focus on employee well-being, long-term financial security, and work-life balance, which is attractive to experienced professionals seeking stability and comprehensive support. The "Unlimited PTO with enforced minimum" is a progressive policy designed to encourage restorative time off.

🎯 Team & Company Context

🏢 Company Culture

Industry: Defense Technology / Aerospace / Robotics / Autonomous Systems. HavocAI operates at the cutting edge of military and commercial autonomous systems, developing solutions for complex, contested environments. This industry demands high levels of innovation, reliability, and adherence to stringent performance standards.

Company Size: A growing startup, founded in 2024. This implies a dynamic, fast-paced environment where individual contributions have a significant impact, and roles may evolve rapidly.

Founded: