Senior Staff DFM Manufacturing Engineer

Duties

• Lead DFX efforts with design engineering teams throughout product development to provide expert DFM and DFA input for machined components, ensuring they can be efficiently produced and serviced.
• Serve as the primary point of contact for design engineers to interpret technical drawings and reconcile manufacturing constraints with performance requirements.
• Apply expert knowledge of GD&T to define inspection protocols and verify that machined components meet rigorous dimensional and performance standards.
• Lead troubleshooting efforts for system and process related issues, identifying root causes and implementing corrective actions to improve yield and part quality.
• Champion Lean Manufacturing initiatives within the precision shop to reduce cycle times and enhance material flow.
• Create and maintain detailed process documentation, setup sheets, and work instructions for machinists.
• Mentor and coach junior engineers and technicians on DFX, good manufacturing practices, technical documentation.

Requirements

• Bachelor’s or Master’s degree in Mechanical, Manufacturing, Industrial Engineering, or a related field, or equivalent experience.
• At least 10 years of relevant experience in manufacturing engineering, process development, or advanced manufacturing, specifically within a machining-intensive environment.
• Expert-level understanding of precision machining capabilities (e.g., multi-axis milling, turning, grinding) and the physical constraints of various materials.
• Strong proficiency in CAD software (SolidWorks, CATIA, or similar) for fixture design and review of engineering drawings.
• Deep understanding of Geometric Dimensioning & Tolerancing (ASME Y14.5) and its application in both design for manufacturing and inspection.
• Proven ability to provide constructive technical feedback and influence design stakeholders across engineering, manufacturing, and leadership teams.
• Exceptional troubleshooting skills with a hands-on approach to resolving mechanical and process-related challenges.

Qualifications

• Comfortable working in a fast-paced, iterative R&D setting where designs and processes evolve rapidly.
• Experience building process controls and quality systems (e.g., 8D, RCCA) to ensure build quality and alignment with performance requirements.
• Nice to have experience supporting robotics or aerospace development programs specifically within an NPI (New Product Introduction) context.
• Advanced knowledge of CAM software (e.g., Hypermill, Cimatron, Esprit) and CNC programming.
• Experience with additive manufacturing or rapid prototyping as a complement to traditional machining.
• Familiarity with PLM systems (e.g., Arena, Enovia) for engineering change control and documentation management.
• Experience with cobots and automation systems (e.g., Universal Robotics, FANUC).