Lead Manufacturing Engineer, DFMA - Joining

About Mach Industries

Founded 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.

Our 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.

The Role

As Lead Manufacturing Engineer, Joining, you'll be Mach's go-to expert on how our vehicles are held together: when to bolt, rivet, bond, or combine methods. You'll own torque tooling and adhesive dispense standards in Mach's prototype factory. That means selecting, buying and deploying the tools our technicians use to build every vehicle, and making sure each joint is tightened right, every torque curve is reported, and every bead of adhesive meets profile inspection criteria. 

You'll push the field forward through research and development (R&D) on new materials, hardware and processes; from designing experiments, to building test articles, partnering with suppliers and moving what works into production. This is a hands-on technical leadership role with direct reports. This role will work closely with Design Engineering, Vehicle Assembly ME, Prototype Factory operations, Quality, Supply Chain and Production to achieve overall production ramp goals across Mach’s factories.

Key Responsibilities

Own the Joining DFMA guide

• Write, publish and maintain Mach's Joining DFMA guide. It should cover:
  • design rules, with the reasoning and test data behind them
  • preferred fasteners, adhesives and joining processes
  • standard joint features and tolerances
  • worked examples and review checklists
• Own Mach's preferred fastener and adhesive lists. Cut unique part numbers and drive commonality across programs.
• Define joint design rules:
  • fasteners: preload and torque, edge distance and pitch, thread engagement, inserts and locking methods
  • galvanic compatibility
  • bondlines: overlap, thickness control and surface prep
• Set standards for automated fastening and dispensing: torque-angle monitoring, auto-feed fasteners, bead geometry and in-process inspection.
• Define the DFMA sign-off criteria for design gates and hold programs to them.
• Set and track DFMA metrics for each program, such as part count, unique fastener count, assembly time, first-pass yield and cost.
• Keep the guide current with test results, production lessons and supplier input. Train design and manufacturing engineers to apply it.

Own torque tooling in the prototype factory

• Own torque tooling procurement: write tool specs, choose vendors, run quotes, manage lead times and own the tooling budget.
• Deploy tools on the floor:
  • set up tool programs and torque strategies (torque, torque-angle, yield control)
  • connect tool controllers to the production tracking system (MES) so every result is recorded
• Build torque mistake-proofing into each station, such as socket selectors, fastener count checks, and interlocks that run the right tool program for each joint.
• Run the torque tool calibration and maintenance program. Verify tool capability on real joints and set residual (audit) torque checks with Quality.

Shape designs early

• Review vehicle architecture and material choices at concept, before designs lock, with an eye to how parts will be joined.
• Run DFMA studies at the part, assembly and system level, and give design teams specific feedback backed by data.
• Drive content reduction, simpler assembly and build-in-quality. Push for wider tolerances where performance allows, and for joints that suit automation.
• Lead value engineering on released designs: challenge assumptions and take out cost.

Enable trade studies and make vs. buy

• Set the rules for choosing adhesive, mechanical or hybrid joints.  Develop the data, cost models and decision criteria for adhesive-vs-fastener and other trade studies.
• Build should-cost, cycle-time and rate models that show how joining choices affect cost, capital investment, schedule and quality.

Lead R&D

• 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.  Write process specs, and define qualification and acceptance criteria.

Required Qualifications 

• 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. This includes taking hardware from design into production at rate in automotive, aerospace, defense or consumer electronics.
• Deep knowledge of bolted joint analysis (for example, VDI 2230) and bonding science (surface prep, cure kinetics, failure modes).
• Hands-on experience selecting, specifying and deploying torque tooling, including:
• Hands-on joint testing (for example, ASTM D1002 lap shear and peel testing) and failure analysis.
  • DC electric nutrunners, pulse tools and transducerized wrenches
  • tool controllers and torque strategies
  • tool capability studies and calibration
• A 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 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, Mechanical Engineering or a related field.
• Experience with major torque tool platforms (for example, Atlas Copco, Desoutter, Cleco or Stanley) and connecting tool data to an MES.
• Knowledge of torque tool standards, such as ISO 6789 for hand torque tools and ISO 5393 for power tool performance.
• Experience setting up tooling in a new prototype or production factory, including owning the 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 (for example, Boothroyd Dewhurst), should-cost modeling.
• Experience leading DFMEAs and PFMEAs.
• Patents, publications, or processes you developed and put into production.
• Experience standing up a lab, test capability, production line at a fast-moving company.
• Experience in an AS9100 or defense production environment.
• Lean or Six Sigma certification.

Additional Requirements

• Available to work extended hours and weekends as needed.

ITAR Requirements

To 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.  

Senior Engineer

$140,000—$180,000 USD

At 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.

Key Elements of Our Compensation Philosophy:

• Competitive Salaries: We continuously research market rates to ensure our salaries are competitive with those in our industry and geographic location.
• Performance-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.
• Equity Participation: We offer stock options or equity to employees, ensuring that you share in the success and growth of the company.
• Benefit 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.
• Professional Development: We allocate funds for continuing education, training, and career growth.
• Transparency: We are committed to openness about our compensation tiers and how decisions are made, ensuring trust and mutual respect.

By 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.

Data Privacy

To view Mach Industries candidate data privacy policy, please visit https://machindustries.com/privacy-policy.

Disclosures

This 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.

Mach 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.

The 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.

Mach 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. If you’d like to defend the American way of life, please reach out!