A vital requirement of the modern combat environment is to gain and maintain situational awareness to facilitate effective squad-level decision making. This paper presents a part of the research undertaken by Georgia Institute of Technology (Georgia Tech) in collaboration with the Army Research Laboratory (ARL) in developing design capabilities for small unmanned aerial systems (sUAS). As part of this effort the team developed a toolset capable of creating mission-specific fixed wing aircraft assets that can be rapidly tailored and manufactured at a forward operating base. The toolset includes a physics-based analysis model to generate feasible aircraft designs from a family of designs, a decision making tool to select the optimal design for a mission, and a parametric CAD model. The CAD model accepts sizing parameters from the design algorithm and uses them to scale baseline part files, which can then be used to rapidly manufacture vehicle parts. Several sets of mission requirements were chosen, leading to unique fixed wing aircraft designs which were manufactured and flown. The process described herein can be used to develop and fabricate small unmanned airplane designs to fulfill rapidly changing squad-level mission-specific operational needs, but can also be applied to other vehicle architectures.