Design for Manufacturing (DFM / DFA) Engineer
Confirmed on the employer's own hiring board on Nov 6, 2026. First seen by Alion on Nov 5, 2026. SEGULA Technologies scores A on the Alion truth index.
DFM & Process Feasibility Analysis: Perform comprehensive DFM/DFA analysis on 3D CAD models (components, sub-assemblies, systems) during early gateway phases (Concept, Detailed Design, Pre-Production). Evaluate draft angles, wall thickness variations, parting lines, rib designs, undercut conditions, bend radii, draw depths, and weld flanges across stamping, molding, casting, sheet metal, and additive processes.
Assembly Feasibility & Clearance Validation: Assess manual and automated assembly feasibility; verify operator hand clearance, tool access envelope (gun clearance, torque tool reach), blind assembly risks, and ergonomics. Drive part count reduction, modularization, fastener standardization, snap-fit integration, and error-proofing (Poka-Yoke design).
Tolerance Stack-Up & GD&T Optimization: Review 2D drawings and 3D PMI to ensure compliance with ASME Y14.5 / ISO standards. Conduct 1D, 2D, and 3D tolerance stack-up simulations (e.g., 3DCS, VSA) to identify variation risks impacting fit, flush, gap, and functional assembly tolerances.
Tooling & Fixture Integration: Coordinate with stamping die designers, mold toolmakers, weld fixture designers, and automation engineers to validate part geometries against tooling and clamping constraints. Feed early manufacturing failure modes into DFMEA/PFMEA.
Cross-Functional Design Reviews & Resolution: Generate detailed DFM scorecards, marked-up CAD models, and issue tracking logs. Participate actively in design reviews with Product Development (PD), Manufacturing Engineering (ME), and Tier-1 Suppliers to negotiate engineering change requests (ECRs/ECNs).
Flexibility of Scope: This position is not limited to the above scope only; based on program needs, the resource may be required to perform other related design/process engineering activities.