Wire Harness Engineer

Overview

CHAOS Industries is redefining modern defense with omniscient systems purpose-built for today’s realities. Designed and built by top U.S. military veterans and Silicon Valley innovators, CHAOS Industries’ products are powered by CDN™, empowering warfighters, commercial air operators, and border protection teams to act faster, adapt rapidly, and stay ahead of evolving threats.

Role Overview : CHAOS is seeking an Electrical or Mechanical Engineer with a focus on Wire Harness / Interconnect design to support the design, development, and integration of wiring solutions for aerospace and defense platforms. This role involves designing power, digital, analog, and RF interconnects from circuit card assemblies (CCAs) through platform-level wiring integration, including routing, mechanical integration, and signal integrity considerations.

• Design wire harnesses and flex circuits, including schematic development, cable routing, connector selection, and harness assembly drawings for CCAs, subsystem, and platform-level applications
• Perform wiring layout and routing for high-voltage/current systems, high-speed data buses, and mixed-signal designs
• Create and maintain wiring diagrams, harness drawings, BOMs, and interface documentation
• Conduct analysis and define program-specific testing procedures for wire harnesses to ensure compliance with performance, safety, and applicable standards
• Support design verification, assembly, test, and integration of wiring and interconnects
• Participate in design reviews, failure mode analysis, and compliance assessments related to military and aerospace standards
• Assist in design for manufacturability and transition to production, including vendor and supplier collaboration
• Opportunity to contribute to adjacent electrical or mechanical design tasks as program needs evolve
• Bachelor’s degree in Electrical Engineering, Mechanical Engineering, or related field
• 2+ years of experience in wire harness, cable assembly, or interconnect design for aerospace, defense, or high-reliability electronics
• Experience with wire harness design tools, such as Siemens Capital or equivalent
• Practical understanding of signal integrity implications, including cable selection, wire routing, controlled impedance, shielding, and EMC considerations
• Exposure to conducting signal integrity analysis for wire harnesses and interconnects
• Familiarity with harness test and inspection requirements and techniques to verify compliance with applicable standards, safety regulations, and performance requirements
• Familiarity with one or more industry standards such as MIL-STD-1553, IPC/WHMA-A-620, RTCA/DO-160, and quality frameworks such as ISO 9001
• Working knowledge of lab instruments, including oscilloscopes, spectrum analyzers, and electronic loads
• Knowledge of high-reliability design practices, derating guidelines, and environmental qualification considerations
• Strong understanding of connectors, terminations, strain relief, and mechanical integration of cables
• Ability to execute assigned design tasks and collaborate with cross-disciplinary teams
• Ability to obtain and maintain a U.S. security clearance

• 2+ years of experience in wire harness, cable assembly, or interconnect design for aerospace, defense, or high-reliability electronics
• Experience with wire harness design tools, such as Siemens Capital or equivalent
• Practical understanding of signal integrity implications, including cable selection, wire routing, controlled impedance, shielding, and EMC considerations
• Exposure to conducting signal integrity analysis for wire harnesses and interconnects
• Familiarity with harness test and inspection requirements and techniques to verify compliance with applicable standards, safety regulations, and performance requirements

• Experience with platform-level wiring integration in vehicles, aircraft, or ground systems
• Experience with rigid-flex harness design and PWB manufacturing processes
• Hands-on experience with flex circuits, discrete wiring, high-voltage/high-current power distribution, and high-speed signal harnesses
• Experience conducting signal integrity analysis for wire harnesses and interconnects
• Proficiency with Altium Designer schematic capture and PCB layout
• Familiarity with automated harness manufacturing tools and processes
• Experience supporting field installation, retrofit, or sustainment activities

• 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: 200 employees and counting across 5 global offices