Rapid Prototyping Engineer – Drones & Unmanned Systems

About the role

HavocAI is seeking a Senior Rapid Prototyping Engineer to lead the technical maturation of Locust, an advanced unmanned aircraft system, as it moves from a demonstrated prototype to a Department of Defense fieldable Low‑Rate Initial Production platform. The position is highly hands‑on, turning early concepts into functional drone prototypes and integrating mechanical and electrical systems.

Key responsibilities

• Rapidly convert concepts and requirements into functional drone prototypes.
• Design and modify airframes, mechanisms, brackets, mounts, enclosures, payload interfaces, and other vehicle components.
• Build and assemble prototype unmanned aircraft and subsystems, integrating motors, propulsion, batteries, avionics, sensors, compute hardware, communications, and payloads.
• Create quick‑turn CAD designs and detailed engineering drawings.
• Utilize additive manufacturing, CNC machining, sheet‑metal work, composites, and other fabrication methods to produce prototype parts.
• Perform hands‑on fabrication, assembly, rework, and modification of prototype hardware.
• Develop test fixtures and experimental setups; support bench, ground, environmental, and flight testing.
• Diagnose mechanical and electromechanical integration failures and rapidly redesign components based on test results.

Required profile

• BS in Mechanical Engineering, Aerospace Engineering, Robotics, Mechatronics, or equivalent practical experience.
• 3+ years of experience developing physical hardware systems.
• Proven track record building and testing drones, UAVs, robotics, aircraft, or autonomous systems.
• Strong mechanical CAD skills and extensive hands‑on experience with electromechanical prototypes.
• Comfortable using common shop tools and performing prototype assembly and modification.

Required skills

• Mechanical CAD (e.g., SolidWorks, CATIA)
• Additive manufacturing (3D printing)
• CNC machining
• Sheet‑metal and composite fabrication
• Motor and propulsion system integration
• Battery and power‑management integration
• Avionics, sensor, and compute hardware integration
• Communications and payload integration
• Test fixture development and experimental setup
• Bench, ground, environmental, and flight testing
• Troubleshooting mechanical and electromechanical systems
• Prototyping shop tools and assembly techniques