In Phase II of the Micro-Autonomous Systems Research project, the Georgia Tech teams developed an automated product family engineering process and toolset allowing the creation of tailored one-off solutions to soldier needs. The toolset provides a simplified user interface for non-technical users to enter vehicle requirements, such as sensor packages, endurance, payload, etc. A spreadsheet logistics interface allows an untrained logistics operator to enter machines and parts availability. This information is fed to set of engineering analyses where a feasible design (if possible) is generated, and the drawings for manufacture are output. These part designs are then provided to a technician with automated manufacturing tools (such as 3D printing) who starts the automated manufacturing, assembles components, and returns the tailored UAV to the soldier. This process has been tested and validated via flight tested vehicles and satisfies the desire to be more responsive to soldier needs for small unmanned aerial systems.