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Salary: USD 140,000 - 180,000 / annual
Mach Industries, founded in 2023, is a rapidly growing defense technology company developing next-generation autonomous defense platforms. With ~350 employees, the company operates with startup agility while focusing on scalable, decentralized defense systems for the U.S. and allies.
This is a hands-on technical leadership role managing a team focused on designing avionics, electronics, harnesses, and avionics boxes for manufacturability and serviceability. Mach builds unmanned defense systems at unprecedented speed, requiring designs optimized for fast, error-free production and field maintenance.
Key Responsibilities:
Own the Avionics DFMA Guide: Write, publish, and maintain Mach's comprehensive Avionics Design-for-Manufacturing and Assembly (DFMA) guide covering design rules with test data, preferred components/connectors/processes, standard features/tolerances, worked examples, and review checklists.
Set Manufacturing Standards: Define design-for-manufacturing (DFM), design-for-assembly (DFA), and design-for-test (DFT) rules for PCBAs, wire harnesses, connectors, and avionics enclosures. Establish connector retention, mate-assurance standards (two-stage CPA clips, TPA locks), and full-mate indicators. Define connection verification methods (push-pull-push checks, vision checks, electrical continuity tests) and DFMA sign-off criteria for design gates.
Shape Designs Early: Review vehicle and electrical architecture at concept stage before designs lock. Lead static and kinematic assembly studies (virtual builds) to check harness routing, install paths, and hand/tool access. Drive content reduction, simpler assembly, build-in-quality, and ergonomic access. Define avionics poka-yoke standards (connector keying, clocking, blind-mate installation).
Value Engineering & Cost Modeling: Lead value engineering on released designs. Build should-cost, cycle-time, and rate models showing how design choices affect cost, capital investment, schedule, and quality. Write manufacturing requirements in RFQ packages and evaluate supplier quotes.
Lead R&D: Conduct R&D on automated harness fabrication, flex/rigid-flex circuits, simpler interconnects, and faster-curing potting/coatings. Develop connector and CPA designs with automatic full-mate confirmation. Plan and run designed experiments (DOE), build test articles, analyze results, and publish findings. Co-develop new components and processes with suppliers, contract manufacturers, equipment makers, universities, and national labs. Lead manufacturing trials during prototype/validation builds.
Support Production: Assess contract manufacturers, harness shops, and connector suppliers on-site. Bring avionics expertise to design and process FMEAs (DFMEAs and PFMEAs). Maintain a library of known failure modes and proven controls. Lead root cause analysis on escapes and repeat defects. Mentor engineers and help build Mach's DFMA function.
Required Qualifications:
- BS in Electrical, Mechanical, Manufacturing, or Industrial Engineering, or equivalent
- 8+ years in avionics, PCBA, or harness manufacturing or design engineering, including taking hardware from design into production at rate in aerospace, defense, automotive, or consumer electronics
- Working knowledge of IPC-A-610, J-STD-001, and IPC/WHMA-A-620
- Experience with SMT processes, box build, and electrical test
- Track record of writing design standards, guides, and process specs
- Strong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics, and ROI
- Working knowledge of GD&T (ASME Y14.5) and tolerance stack-ups
- Skilled in 3D CAD (NX, CATIA, SolidWorks, or similar) and comfortable in ECAD tools
Preferred Qualifications:
- MS in Electrical Engineering or related field
- Knowledge of automotive connector standards (SAE/USCAR-2, USCAR-25) and MIL-spec connectors (MIL-DTL-38999)
- Experience with automotive high-volume harness and connector systems
- Experience ruggedizing defense electronics (MIL-STD-810, shock and vibration)
- IPC CIS or CIT certification
- Experience with high-rate automotive or consumer electronics production
- Formal DFMA methods (Boothroyd Dewhurst), should-cost modeling, and value engineering programs with measured savings
- Experience leading DFMEAs and PFMEAs
- Patents, publications, or processes developed and put into production
- Experience in AS9100 or defense production environment
- Lean or Six Sigma certification
Additional Requirements:
- Available to work extended hours and weekends as needed
- ITAR Compliance: Must be U.S. citizen, national, lawful permanent resident, Refugee, or Asylee, or eligible to obtain required authorizations from U.S. Department of State
