{"id":2058456,"url":"https://alion.io/job/mach-industries-lead-manufacturing-engineer-dfma-avionics","title":"Lead Manufacturing Engineer, DFMA - Avionics","company":{"id":4935,"name":"Mach Industries","domain":"machindustries.com","url":"https://alion.io/company/machindustries","size_band":"201-500","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":{"grade":"A","score":100,"open_postings":4,"ghost_share":0,"stale_share":0,"repost_share":0,"time_to_fill_p50_days":44,"computed_at":"2026-10-27T05:46:45Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"lead","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"explicit","locations":["Huntington Beach, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":140000,"max":180000,"currency":"USD","period":"year","gross":null,"usd_annual":180000},"salary_estimate":null,"experience_years_min":null,"visa_sponsorship":true,"relocation_package":false,"has_equity":true,"technologies":[{"name":"CATIA","optional":false},{"name":"SolidWorks","optional":false},{"name":"AS9100","optional":true},{"name":"MIL-STD-810","optional":true}],"status":"live","first_seen_at":"2026-10-08T00:05:27Z","employer_posted_date":"2026-10-08","last_verified_at":"2026-10-27T02:58:34Z","board_verified":true,"closed_at":null,"days_open":19,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":19},"description":"About Mach Industries\nFounded in 2023, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 350 employees, we operate with startup agility and ambition.\nOur vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security.\nThe Role\nGreat hardware balances performance, manufacturability and serviceability. Mach is building unmanned defense systems at a rate the traditional defense industrial base was never designed for. That takes designs that are built to be built: fast, right the first time, at the lowest cost, and easy to maintain in the field.\nThis is a hands-on technical leadership role with direct reports. As Lead Manufacturing Engineer, Avionics, you'll be Mach's go-to expert on designing electronics, harnesses and avionics boxes so they can be built, tested, installed and maintained quickly and without errors. You'll write Mach's Avionics DFMA guide. You'll push the field forward through research and development (R&D) on new materials, hardware and processes.\nKey Responsibilities\nOwn the Avionics DFMA guide\nWrite, publish and maintain Mach's Avionics DFMA guide. It should cover:design rules, with the reasoning and test data behind them\npreferred components, connectors, wire and processes\nstandard features and tolerances\nworked examples and review checklists\n\nWrite design-for-manufacturing, assembly and test rules (DFM, DFA, DFT) for PCBAs, wire harnesses, connectors and avionics enclosures (box build).\nSet connector retention and mate-assurance standards:two-stage connector position assurance (CPA) clips that ship pre-staged\nterminal position assurance (TPA) locks to confirm every terminal is fully seated\naudible, tactile and visual full-mate indicators, such as color-coded CPAs\nlimits on mating and CPA engagement force (for example, per SAE/USCAR-25)\n\nDefine how each connection is checked at the station: push-pull-push checks, CPA position checks by vision, and electrical continuity or mate-detect tests.\nDefine the DFMA sign-off criteria for design gates and hold programs to them.\nSet and track DFMA metrics for each program, such as part count, unique connector count, assembly and test time, first-pass yield and cost.\nKeep the guide current with test results, production lessons and supplier input. Train design and manufacturing engineers to apply it.\nShape designs early\nReview vehicle and electrical architecture at concept, before designs lock: box placement, harness layout and connector strategy.\nLead static and kinematic assembly studies (virtual builds) before hardware exists. Check harness routing, install paths, and hand and tool access to mate each connector and seat its CPA. Set harness routing, retention and installation rules.\nDrive content reduction (fewer connectors, wires and boards), simpler assembly, build-in-quality and ergonomic access. Push for features that suit automation.\nDefine avionics poka-yoke standards, for example:connector keying and clocking\na unique connector per interface\ntwo-stage CPA clips and TPA locks\nblind-mate or tool-less installation\n\nLead value engineering on released designs: challenge assumptions and take out cost.\nEnable trade studies and make vs. buy\nBuild should-cost, cycle-time and rate models that show how design choices affect cost, capital investment, schedule and quality.\nWrite the manufacturing requirements in RFQ packages for contract manufacturers and help evaluate supplier quotes.\nLead R&D\nLead R&D on automated harness fabrication, flex and rigid-flex circuits that replace harnesses, simpler interconnects, and faster-curing potting and coatings.\nDevelop connector and CPA designs that confirm a full mate automatically, through vision or electrical mate detection.\nPlan and run designed experiments (DOE). Build test articles, test to failure, analyze results with sound statistics, and publish findings.\nCo-develop new components, processes and equipment with suppliers, contract manufacturers, equipment makers, universities and national labs.\nLead manufacturing trials during prototype / validation builds to prove new processes.\nSupport production and suppliers\nAssess contract manufacturers, harness shops and connector suppliers on site, and push them toward best practices and lower investment.\nWork with connector suppliers on CPA and TPA design and qualification.\nBring avionics expertise to design and process FMEAs (DFMEAs and PFMEAs). Maintain a library of known failure modes and proven controls.\nLead root cause analysis on escapes and repeat defects, e.g. partially mated connectors, solder defects, miswires / connector damage. Feed fixes into the guide.\nMentor engineers and help build Mach's DFMA function.\nRequired Qualifications \nBS in Electrical, Mechanical, Manufacturing or Industrial Engineering, or equivalent. \n8+ years in avionics, PCBA or harness manufacturing or design engineering. This includes taking hardware from design into production at rate in aerospace, defense, automotive or consumer electronics.\nWorking knowledge of IPC-A-610, J-STD-001 and IPC/WHMA-A-620.\nExperience with SMT processes, box build and electrical test.\nA track record of writing design standards, guides, process specs.\nStrong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics and ROI.\nWorking knowledge of GD&T (ASME Y14.5) and tolerance stack-ups.\nSkilled in 3D CAD (NX, CATIA, SolidWorks or similar) and comfortable in ECAD tools.\nPreferred Qualifications\nMS in Electrical Engineering or a related field.\nKnowledge of automotive connector standards (for example, SAE/USCAR-2 and USCAR-25) and MIL-spec connectors (for example, MIL-DTL-38999).\nExperience with automotive high-volume harness and connector systems.\nExperience ruggedizing defense electronics (MIL-STD-810, shock and vibration).\nIPC CIS or CIT certification\nExperience with both high-rate automotive or consumer electronics production\nFormal DFMA methods (for example, Boothroyd Dewhurst), should-cost modeling, and value engineering programs with measured savings.\nExperience leading DFMEAs and PFMEAs.\nPatents, publications, or processes you developed and put into production.\nExperience in an AS9100 or defense production environment.\nLean or Six Sigma certification.\nAdditional Requirements\nAvailable to work extended hours and weekends as needed\nITAR Requirements\nTo conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here. \nSenior Engineer\n$140,000—$180,000 USD\nAt Mach, we believe that compensation is more than just a paycheck. It's a comprehensive package designed to reward the time, skills, and expertise you bring to our team. We are committed to offering competitive compensation that is equitable, transparent, and aligned with market trends.\nKey Elements of Our Compensation Philosophy:\nCompetitive Salaries: We continuously research market rates to ensure our salaries are competitive with those in our industry and geographic location.\nPerformance-Based Incentives: Our bonus structure is tied to both individual and company performance, creating a win-win scenario that motivates our team members to excel.\nEquity Participation: We offer stock options or equity to employees, ensuring that you share in the success and growth of the company.\nBenefit Packages: Our benefits include healthcare, dental and vision plans, retirement savings, and paid time off, because we understand that your well-being extends beyond the office.\nProfessional Development: We allocate funds for continuing education, training, and career growth.\nTransparency: We are committed to openness about our compensation tiers and how decisions are made, ensuring trust and mutual respect.\nBy joining Mach, you’re not just accepting a job-you’re becoming a key part of a team that values your contributions and invests in your growth. Together, we aim to create a rewarding environment that sets the stage for long-term success.\nData Privacy\nTo view Mach Industries candidate data privacy policy, please visit https://machindustries.com/privacy-policy.\nDisclosures\nThis position may require access to information protected under U.S. export control laws and regulations, including the Export Administration Regulations (EAR) and the International Traffic in Arms Regulations (ITAR). Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these U.S. export control laws and regulations without sponsorship for an export license.\nMach participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.\nThe salary range for this role is an estimate based on a wide range of compensation factors, inclusive of base salary only. Actual salary offers may vary based on (but not limited to) work experience, education and training, critical skills, and business considerations. Highly competitive equity grants are included in most offers and are considered part of Mach’s total compensation package. Mach offers benefits such as health insurance, retirement plans, and opportunities for professional development.\nMach is an equal opportunity employer committed to creating a diverse and inclusive workplace. All qualified applicants will be treated with respect and receive equal consideration for employment without regard to race, color, creed, religion, sex, gender identity, sexual orientation, national origin, disability, uniform service, Veteran status, age, or any other protected characteristic per federal, state, or local law, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws. 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