Staff Manufacturing Engineer

About the Role

As a Staff Manufacturing Engineer at Boston Dynamics, you will help build and enhance our development plant's manufacturing systems to enable predictable production outputs. You will work on introducing changes to our robots, stabilizing and ramping up production, and managing continuous improvement. Collaborating with Quality, Test, and OPM teams, you will define and solve production problems while driving efficiency and stability in a fast-paced New Product Introduction environment.

Responsibilities

• Collaborate with Hardware Engineering to provide DFM/DFA (Design for Manufacturing & Assembly) input throughout product development, ensuring manufacturability and serviceability.
• Design, fabricate, and validate custom fixtures, tools, and jigs to support mechanical assembly, precision alignment, and testing of electric motors and actuators, ensuring ergonomic and repeatable processes.
• Define assembly sequences, work instructions, and process documentation, including standard operating procedures (SOPs), visual aids, and training materials for assembly technicians.
• Support prototype builds in a hands-on capacity, troubleshooting assembly issues, identifying root causes, and driving corrective actions to improve processes and product designs.
• Implement process controls to ensure build quality, dimensional accuracy, and alignment with product performance requirements.
• Lead continuous improvement initiatives, applying Lean Manufacturing and Six Sigma methodologies to improve process efficiency, reduce cycle times, and increase yield.
• Drive tooling and equipment validation, ensuring custom fixtures and tools are fully qualified for use in production, including performing capability studies where necessary.

Requirements

• Bachelor's degree in Manufacturing, Mechanical, Industrial, Electrical Engineering, or a related field; Master’s degree a plus.
• At least 5 years of relevant experience in manufacturing engineering, process development, or advanced manufacturing, preferably in robotics, aerospace, or complex electromechanical systems.
• Strong proficiency in CAD software (SolidWorks, CATIA, or similar) for tool/fixture design and review of engineering drawings, and a strong understanding of GD&T (Geometric Dimensioning & Tolerancing).
• Experience with creating and approving change orders associated with products, procedures, and BOMs.
• Proven track record of DFM/DFA collaboration with design teams to drive manufacturable and serviceable product designs.
• Hands-on experience with additive manufacturing, rapid prototyping, machining (e.g., Mill, Lathe), and fabrication (e.g., Welding, Grinding, Bending) techniques for developing and validating custom tooling, jigs, and fixtures.
• Experience writing clear, concise, and detailed work instructions, SOPs, and training materials for assembly technicians.
• Experience working in production environments, with an ability to adapt processes for continuously evolving product designs.
• Demonstrated experience applying Lean Manufacturing, Six Sigma, and root cause analysis methodologies to drive process improvement.
• Excellent problem-solving skills with the ability to troubleshoot complex mechanical and electromechanical assemblies.
• Comfortable working in cross-functional teams, balancing technical, schedule, and cost considerations in a fast-paced environment.
• Strong communication skills, with the ability to present technical concepts and influence stakeholders across engineering, operations, and leadership teams.
• Experience supporting on-site prototype builds and providing direct manufacturing floor support, balancing countermeasures and corrective actions.

Nice to Have

• Experience supporting robotics development programs, particularly New Product Introduction (NPI).
• Experience with Product Lifecycle Management (PLM) systems for engineering change control and manufacturing documentation management (e.g., Arena, Enovia).
• Experience with Manufacturing Execution Systems (MES)/Platforms (e.g., Tulip, Delmia).
• Experience working in a research-to-product transition environment, where designs and processes evolve rapidly.
• Experience in design for mass production of multi-part products and assemblies (DFM, DFA).
• Working experience with quality processes and systems (process control, 8D and other RCCA frameworks, etc.).

Pay

The base pay range for this position is between $116,000.00 and $140,000.00. Base pay will depend on multiple individualized factors including, but not limited to, internal equity, job-related knowledge, skills, and experience.