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Salary: USD 140,000 - 180,000 / annual
Mach Industries, founded in 2023, is a rapidly growing defense technology company with ~350 employees focused on next-generation autonomous defense platforms. This role is a senior individual contributor position reporting to engineering leadership.
You will be Mach's go-to expert on designing composite structures for high-rate production, reviewing designs from concept through production release at part, assembly, and system levels. You will also lead research and development on new materials, hardware, and processes—designing experiments, building test articles, partnering with suppliers, and moving innovations into production.
Key responsibilities include:
**Own the Composites DFMA Guide**: Write, publish, and maintain Mach's Design for Manufacturing and Assembly (DFMA) guide for high-rate composite production, including design rules for each process with supporting data, preferred materials and processes by part type, standard features and tolerances, and worked examples with review checklists. Develop specific design rules for liquid composite molding (LCM) processes including RTM, HP-RTM, C-RTM, and wet compression molding, covering preform design, gate/vent/flow-path design, wall thickness, transitions, and net-shape vs. trimmed edges. Set rate-capable standards for preforming, injection, cure, demold, trim, drill, and inspection in automated cells. Define DFMA sign-off criteria for design gates and track metrics including part count, cycle time, material utilization, first-pass yield, scrap rate, and cost.
**Shape Designs Early**: Advise on vehicle architecture and material/process choices before designs lock. Match each part to the right high-rate process early and design to that line's capability. Drive part consolidation through molded-in features and co-molded assemblies. Define composites error-proofing standards (poka-yoke) such as asymmetric locators, in-line vision checks, insert-presence sensing, and mold-close interlocks. Lead value engineering on released designs to challenge assumptions and reduce cost.
**Enable Trade Studies and Make vs. Buy**: Develop data, cost models, and decision criteria for metal vs. composite structures, process selection (HP-RTM vs. compression molding vs. AFP/ATL), and in-house vs. outsourced manufacturing. Build should-cost, rate, and material-utilization models showing how design choices affect cycle time, cost, schedule, quality, and capital investment. Support Supply Chain in partner selection and negotiations.
**Prepare Designs for Outsourcing**: Find and assess high-volume composites manufacturers including automotive and industrial suppliers. Build technical data packages with models, drawings, material and process specs, key characteristics, and acceptance criteria. Bridge automotive launch practices (APQP, PPAP) with aerospace and defense quality requirements (AS9100, AS9102).
**Lead R&D**: Set and run a composites R&D roadmap aimed at shorter cycle times, more automation, and less scrap. Lead R&D on snap-cure and fast-cure resins, automated and net-shape preforming, dry-fiber placement for infusion, thermoplastic tape placement and stamping, and cure monitoring with closed-loop process control. Plan and run designed experiments (DOE), build test articles, test to failure, and publish findings.
**Support Production and Suppliers**: Own tooling feasibility, design reviews, and buyoff for matched-metal molds, preform tools, and AFP/ATL tools. Assess tool suppliers on site and push best practices. Bring composites expertise to design and process FMEAs. Mentor engineers and help build Mach's DFMA function.
**Requirements:**
- BS in Mechanical, Materials, or Chemical Engineering, or equivalent experience
- 7+ years in composite manufacturing, process, or design engineering for high-rate production with hands-on experience in at least one of: HP-RTM or other LCM processes, AFP/ATL, or automated preforming/ply pick-and-place
- Launched a high-rate composite part or production line (in-house or at outside manufacturer) including tooling, equipment, run-at-rate, and ramp
- Experience with draping and mold-filling simulation (PAM-RTM or similar) and composite design tools (CATIA Composites Design, Fibersim, or similar)
- Track record of writing design standards, 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, and 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, Aerospace Engineering, or related field
- High-volume automotive composites experience at OEM or Tier 1 supplier (HP-RTM or compression-molded structural parts)
- Experience at composites equipment maker or automation integrator
- Familiarity with automotive launch practices (APQP, PPAP) and aerospace quality systems (AS9100, AS9102)
- Formal DFMA methods (Boothroyd Dewhurst), should-cost modeling, and value engineering with measured savings
- Lean or Six Sigma certification
**Additional Notes:** ITAR-eligible candidates only (U.S. citizen, national, green card holder, refugee, or asylee). Position may require extended hours and weekends as needed.
