Senior Controls & Automation Engineer

Job Overview

We are seeking a Senior Automation & Controls Engineer who applies sound software engineering practices to design and deliver industrial automation systems using the Beckhoff Platform. This role focuses on building reliable, maintainable, and scalable control systems in a real-world manufacturing environment.

You will develop automation solutions that balance deterministic control requirements with modern engineering practices such as modular design, version control, code reviews, and disciplined change management. While the work is rooted in traditional industrial automation, there is an increasing emphasis on improving the development, testing, and deployment of control software.

In this role, you will work across the full lifecycle of automation systems-from electrical design and hardware selection to controls software development, deployment, commissioning, and long-term support. A significant portion of your time, approximately 20-25%, will also be dedicated to the maintenance, improvement, and upgrading of existing equipment. You will collaborate closely with manufacturing, electrical, mechanical, and software teams to ensure systems are safe, reliable, and adaptable to evolving production needs.

The role is based at Mainspring Headquarters in Menlo Park, California, and is primarily on-site with some travel within North America.

Responsibilities

• System Design & Architecture: Lead the design of complex automation systems, including PLCs, HMIs, and robotics. Create and maintain electrical schematics, control enclosure layouts, and wiring diagrams using CAD software
• Programming & Implementation: Program and debug control systems using platforms mainly in Beckhoff products with some possible use of Rockwell , Siemens TIA Portal and Schneider Electric products. Develop and implement closed-loop control systems and novel data structures
• Project Execution: Own specific engineering projects from conception to completion, ensuring timelines, budgets, and quality standards are met. Contributing to the successful completion of projects in a timely fashion
• Continuous Improvement: Analyze existing manufacturing processes to identify inefficiencies and bottlenecks. Conduct root cause analyses and troubleshooting to support process improvements
• Safety & Compliance: Design and deploy personnel safety interlock systems and ensure compliance with industry standards such as NFPA 79, SEMI, and UL508A
• Collaboration & Mentorship: Collaborate with multidisciplinary teams (mechanical, hardware, software) to ensure proper integration of automated systems. You may supervise the activities of a few others or mentor junior staff and technicians

Required Qualifications

• 5-10 years of experience in industrial automation or controls engineering
• Hands-on experience with PLC platforms such as Beckhoff TwinCAT (TwinCAT 3), Allen-Bradley
• Strong proficiency in IEC 61131-3 with emphasis on Structured Text
• Proven experience delivering industrial automation projects in manufacturing or production environments
• Solid understanding of: Industrial sensors and actuators | Electrical control systems and panel design | Industrial networking and fieldbus protocol
• Experience using Git or similar version control systems in a professional environment

Preferred Qualifications

• Experience with motion control, robotics, or high-performance automation systems
• Familiarity with EtherCAT architecture and performance tuning
• Experience with industrial networks (OT networks)
• Experience working alongside MES, SCADA, or higher-level software systems
• Prior experience acting as a technical lead on projects