The R&D Technician – Avionics builds, integrates, tests and maintains the electrical and electronic systems of R&D prototypes. These include UAVs, UAV launch systems, ground control stations and other ground equipment. The technician works hands-on with the avionics engineers, from the first prototype to flight test.
The technician is also the bridge between R&D and Production. When a design is ready for production, the technician helps transfer it: builds the first production units with the assembly team, writes clear work instructions, and trains assembly staff to do wiring, soldering, set-up and calibration correctly the first time.
Key Responsibilities
Prototype Build and Integration
- Build wiring harnesses and cable assemblies from drawings and pin-out tables: cut, strip, crimp, solder, sleeve, lace and label.
- Install and connect avionics in airframes and ground systems, including flight controllers, GNSS and compass units, air data sensors, radios and data links, payloads, ESCs, servos, power distribution units and batteries.
- Assemble and wire ground equipment such as ground control stations, antenna and tracker set-ups, launcher control and power boxes, test benches and test rigs.
- Route and attach cables to protect them from vibration, heat, chafing and electrical noise (EMI); apply correct shielding and grounding.
- Perform through-hole and surface-mount soldering and PCB rework on prototype boards as instructed by hardware engineers.
Test, Calibration and Field Support
- Perform continuity, insulation and power-up tests on harnesses and assemblies before first power-on, and record results.
- Load firmware and parameters on flight controllers and other devices; set up and calibrate sensors and actuators, including accelerometers, compass, airspeed, ESCs, servo travel and direction, and radio links.
- Set up and operate bench tests and hardware-in-the-loop (HIL) test set-ups. Measure voltage, current and signals with the correct test equipment.
- Find and repair electrical faults down to component level and report root cause to the responsible engineer.
- Support ground and flight tests at test sites, including pre-flight checks, radio range checks, battery and power preparation, log download and post-flight checks.
Maintenance and Configuration Control
- Keep R&D prototypes and ground equipment ready for test through scheduled checks, repairs and modifications.
- Maintain records for each prototype, including hardware build state, firmware and parameter versions, modifications, flight hours and defects.
- Manage LiPo and Li-ion batteries: charge, store, cycle, inspect and discard them safely; maintain battery logs.
- Maintain appropriate stocks of connectors, wire, consumables and spare parts, and inform Procurement before stock runs out.
Bridge to Production
- Build the first (pilot) production units with the assembly team and identify design features that make products difficult to build or test.
- Write and validate photo-based work instructions for harness build, installation, set-up and calibration so assembly technicians can follow them independently.
- Prepare harness boards, test fixtures, checklists and acceptance test procedures (ATP) for end-of-line tests.
- Train production and assembly staff in crimping, soldering, connector assembly, wiring, firmware loading, calibration and set-up; check their work and sign them off when competent.
- Support production with technical problems and non-conformance investigations, and share lessons learned with R&D.
Workshop, Safety and Quality
- Keep the avionics workshop clean, safe and organized using 5S practices.
- Follow safety rules for ESD, batteries, high current and radio transmitters.
- Follow company quality procedures and record inspection and test results.
- Ensure crimp tools, torque drivers and test equipment are calibrated and in good condition.
Qualifications And Experience
- Diploma, associate degree or technical certificate in electronics, electrical engineering, avionics, mechatronics or aircraft maintenance.
- Minimum 3 years of hands-on experience in electronics or avionics assembly, integration or maintenance. UAV, aerospace, defence, automotive or robotics experience is preferred.
- An avionics maintenance licence or military avionics experience is an advantage.
- Experience training others or writing work instructions is an advantage.
Essential
Technical Skills
- Read and work from wiring diagrams, schematics, pin-out tables and harness drawings.
- High-quality crimping and soldering, including correct use of crimp tools and common connector types such as JST, Molex, D-sub and circular connectors.
- Use multimeters, oscilloscopes, bench power supplies and insulation testers.
- Basic knowledge of DC power systems, batteries, electric motors and ESCs.
- Basic knowledge of data buses: UART, I²C, SPI, CAN and Ethernet.
- Good computer skills, including installing software, flashing firmware, changing parameters and using MS Office.
Desirable
- PX4 or ArduPilot, with QGroundControl or Mission Planner.
- CAN bus tools and logic analyzers.
- SMD rework using hot air and a microscope.
- RF systems, including antennas, coaxial cables, data and video links, basic range and interference checks.
- Basic Linux command line and simple scripts for flashing and testing.
- Ground control stations, antenna trackers or launcher electrical systems.
Personal Attributes
- Careful and precise, checking work before it moves to the next step.
- Patient teacher who explains tasks step by step and checks understanding.
- Logical problem-solver who records findings and corrective actions.
- Works well in a small team where priorities change quickly and stays calm during test campaigns.
- Good spoken and written English.
Working Conditions
Based in the R&D workshop and laboratories in Masdar City, Abu Dhabi.
Regular work at outdoor test sites in the UAE, sometimes in high heat.
Works with LiPo batteries, high current, solvents and soldering fumes; must follow safety rules and use correct PPE.
Lifts and moves equipment up to 25 kg; uses team lifting or lifting aids for heavier items.
Must pass company security screening. A valid UAE driving licence is an advantage.
How Success Is Measured
- Prototypes are ready for testing on the planned date.
- Builds pass inspection and first power-up without rework.
- Prototype records, including build state, firmware and defects, are complete and accurate.
- Every product transferred to production has released work instructions and an ATP.
- Assembly staff are trained and signed off, and production builds meet quality targets after handover.
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