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Salary: USD 140,000 - 180,000 / annual
Mach Industries, founded in 2023, is a rapidly growing defense technology company (~350 employees) developing next-generation autonomous defense platforms. This is a hands-on technical leadership role focused on manufacturing engineering and design for manufacturability (DFMA) in the prototype factory.
You will own how Mach's vehicles are assembled—deciding when to bolt, rivet, bond, or combine methods. Key responsibilities include:
**Joining DFMA Leadership**: Write, publish, and maintain Mach's Joining DFMA guide covering design rules, preferred fasteners/adhesives, standard joint features, tolerances, and worked examples. Own the preferred fastener and adhesive lists, driving commonality across programs. Define joint design rules for fasteners (preload, torque, edge distance, thread engagement, locking methods) and bondlines (overlap, thickness, surface prep). Set standards for automated fastening and dispensing, including torque-angle monitoring and in-process inspection. Define DFMA sign-off criteria at design gates and set/track DFMA metrics (part count, unique fastener count, assembly time, first-pass yield, cost). Keep the guide current with test results and train design/manufacturing engineers.
**Torque Tooling Ownership**: Own torque tooling procurement (specs, vendor selection, quotes, lead times, budgeting). Deploy tools on the floor by setting up tool programs and torque strategies, connecting tool controllers to the MES, and building mistake-proofing into each station. Run the torque tool calibration and maintenance program, verify tool capability on real joints, and set residual torque checks with Quality.
**Early Design Influence**: Review vehicle architecture and material choices at concept stage with an eye toward joining. Run DFMA studies at part, assembly, and system levels, providing design teams with data-backed feedback. Drive content reduction, simpler assembly, and build-in-quality. Lead value engineering on released designs.
**Trade Studies & Make-vs-Buy**: Set rules for choosing adhesive, mechanical, or hybrid joints. Develop data, cost models, and decision criteria. Build should-cost, cycle-time, and rate models showing how joining choices affect cost, capital, schedule, and quality.
**R&D Leadership**: Set and run a joining R&D roadmap aimed at faster, cheaper, more reliable production. Plan and run designed experiments (DOE), build coupons and test articles, test to failure, analyze results with sound statistics, and publish findings. Release proven processes to production with process specs and qualification criteria.
You will work closely with Design Engineering, Vehicle Assembly ME, Prototype Factory operations, Quality, Supply Chain, and Production to achieve production ramp goals.
**Requirements**:
- BS in Mechanical, Materials, or Manufacturing Engineering, or equivalent experience
- 7+ years of hands-on experience in fastener engineering, adhesive bonding, or joining process engineering, including taking hardware from design into production at rate in automotive, aerospace, defense, or consumer electronics
- Deep knowledge of bolted joint analysis (e.g., VDI 2230) and bonding science (surface prep, cure kinetics, failure modes)
- Hands-on experience selecting, specifying, and deploying torque tooling: DC electric nutrunners, pulse tools, transducerized wrenches, tool controllers, torque strategies, tool capability studies, and calibration
- Hands-on joint testing (e.g., ASTM D1002 lap shear and peel testing) and failure analysis
- Track record of writing design standards, design guides, or process specs
- Strong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics, ROI
- Working knowledge of GD&T (ASME Y14.5), tolerance stack-ups, and DVA
- Skilled in 3D CAD (NX, CATIA, SolidWorks, or similar)
**Preferred Qualifications**:
- MS or PhD in Materials Science, Mechanical Engineering, or related field
- Experience with major torque tool platforms (Atlas Copco, Desoutter, Cleco, Stanley) and connecting tool data to an MES
- Knowledge of torque tool standards (ISO 6789, ISO 5393)
- Experience setting up tooling in new prototype or production factory, including owning equipment budget
- Experience with aerospace fastener standards (NAS, NASM, MS)
- Experience with automotive high-volume joining (self-piercing rivets, flow-drill screws, structural adhesives)
- Nondestructive inspection (NDI) of bonded joints
- Formal DFMA methods (e.g., Boothroyd Dewhurst), should-cost modeling
- Experience leading DFMEAs and PFMEAs
- Patents, publications, or processes developed and put into production
- Experience standing up lab, test capability, or production line at fast-moving company
- Experience in AS9100 or defense production environment
- Lean or Six Sigma certification
**ITAR Requirements**: Applicant must be a U.S. citizen, national, lawful permanent resident, Refugee, or Asylee, or be eligible to obtain required authorizations from the U.S. Department of State.
