Senior Manufacturing Engineer, Radar

Responsibilities

• Lead manufacturing process development for avionics electromechanical assembly, including PCBA integration, conformal coating, potting, wire harness routing, connector termination, and enclosure sealing.
• Design and qualify production tooling, fixtures, automated work cells, and test equipment for precision electromechanical build and functional verification.
• Execute Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, and control plans to drive first-pass yield >95% and aggressive cycle-time reduction.
• Establish statistical process control (SPC), in-process inspection, and metrology strategies for critical avionics parameters (torque, continuity, insulation resistance, leak testing).
• Scale production from low-rate initial production (LRIP) to full-rate manufacturing, including line balancing, capacity modeling, and cost-reduction initiatives.
• Perform root-cause analysis and corrective actions for assembly defects using 8D, fishbone, and fault-tree methods; support MRB/FRB dispositions.
• Author and maintain detailed work instructions, travelers, and quality records compliant with customer requirements.
• Collaborate with suppliers on incoming material qualification for PCBs, connectors, and electromechanical components.
• Drive continuous improvement projects targeting cost, quality, and throughput for next-generation hypersonic avionics programs.

Qualifications

• Bachelor’s in Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, or related field.
• 7+ years in manufacturing engineering for complex aerospace or defense electronics hardware.
• 4+ years specifically supporting avionics or electromechanical assembly and integration (high-reliability electronics preferred).
• Proven success transitioning avionics hardware from prototype through LRIP to full-rate production.

Preferred Skills and Experience

• Proficient with 3D CAD (SolidWorks or NX), GD&T (ASME Y14.5), and tolerance stack-up analysis.
• Strong experience in precision electromechanical assembly processes, including soldering, crimping, potting, adhesive bonding, and cleanroom/ESD protocols.
• Familiarity with ERP/MES systems and manufacturing execution for full aerospace traceability.
• Working knowledge of environmental stress screening (ESS), vibration, thermal cycling, and functional test integration for avionics.
• Experience in fast-paced defense or space environments (e.g., Anduril or SpaceX).
• Background with harsh-environment electronics (high-G, thermal extremes, radiation).
• Experience implementing automation for electromechanical assembly and achieving significant cost or cycle-time reductions.
• Familiarity with ITAR-controlled programs and classified manufacturing protocols.