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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 its allies.
As Lead Manufacturing Engineer for Tooling Design, you will be Mach's expert on tooling design and design-for-automation (DFMA), leading a hands-on technical team. This role bridges design and manufacturing, ensuring parts are optimized for automated assembly and production efficiency.
Key responsibilities include:
**Standards & Guidance**: Own and maintain Mach's Tooling and Design-for-Automation guide, covering design rules with test data, preferred tooling components, standard locating features, tolerances, and worked examples. Write tooling standards for datum strategy, modular fixtures, clamping, and materials. Define metrology and verification standards (laser tracker, CMM, vision systems). Establish DFMA sign-off criteria for design gates.
**Design Review & Optimization**: Review vehicle architecture and material choices at concept stage, focusing on datums, locating, and automated handling. Run DFMA studies at part, assembly, and system levels. Lead static and kinematic assembly studies (virtual builds) to validate robot reach, tool access, and install paths. Drive content reduction, simpler assembly, build-in-quality, and ergonomic access. Challenge tolerances and push for automation-friendly features.
**Trade Studies & Cost Modeling**: Provide tooling cost, lead-time, capital, and rate data for automation trades (manual vs. semi-automated vs. fully automated). Build should-cost and rate models showing how design and automation choices affect cost, capital, schedule, and quality. Lead value engineering on released designs.
**R&D Leadership**: Set and run a tooling and automation R&D roadmap. Lead research on reconfigurable and low-cost fixturing, additive tooling, fixtureless and vision-guided assembly, robotic drilling and fastening. Plan and run designed experiments (DOE). Build test articles and prototype cells. Publish findings and capture inventions for patent protection. Design and deliver prototype tooling for development and validation builds.
**Tool Lifecycle & Supplier Management**: Own the lifecycle of critical tools from feasibility through production handoff. Design and oversee build of critical fixtures, jigs, end effectors, and assembly tooling. Run tool design reviews and buyoffs at tool shops. Bring tooling expertise to design and process FMEAs. Lead root cause analysis on tooling-related escapes.
**Mentorship**: Train design and manufacturing engineers on DFMA principles. Help build Mach's DFMA function.
**Requirements**
- BS in Mechanical, Manufacturing, or Industrial Engineering, or equivalent experience
- 8+ years designing production tooling, fixtures, or end effectors for automated or high-rate assembly in aerospace, automotive, defense, or consumer electronics
- Expert in GD&T (ASME Y14.5), datum schemes, and tolerance stack-ups including dimensional variation analysis
- Experience integrating tooling with robots and automated cells, including equipment selection and ROI justification
- 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
- Skilled in 3D CAD (NX, CATIA, SolidWorks, or similar)
- First-principles thinker with bias for action; challenges assumptions with data
- Comfortable on production floor and in lab
- Clear writer who can influence design decisions
- Available to work extended hours and weekends as needed
- ITAR eligibility required: U.S. citizen, national, lawful permanent resident, Refugee, or Asylee
**Preferred Qualifications**
- Journeyman Tool and Die Maker certification or equivalent toolmaker background
- MS in Mechanical or Manufacturing Engineering or related field
- Experience with both aerospace assembly tooling and automotive assembly automation
- Familiarity with PLCs, robot programming, and machine safety standards
- Large-scale metrology experience
- Formal DFMA methods (e.g., Boothroyd Dewhurst), should-cost modeling, value engineering with measured savings
- Assembly and robot simulation tools (e.g., Siemens Process Simulate, DELMIA)
- Leadership of DFMEAs and PFMEAs
- Patents, publications, or processes developed and put into production
- AS9100 or defense production environment experience
- Lean or Six Sigma certification
