Principal Process Engineer

Twenty-Six Defense • Fort Worth, TX

3d

About The Position

The Principal Process Engineer serves as the highest technical authority for Circuit Card Assembly (CCA) manufacturing within the Center of Excellence. The role provides expert-level leadership in advanced process development, cross-functional project execution, and technology advancement for high-reliability defense and aerospace electronics. The Principal Engineer leads initiatives to improve quality, yield, reliability, and cost performance while ensuring compliance with IPC, J-STD, and MIL standards. This position requires deep subject-matter expertise, experience leading complex technical projects, and the ability to influence engineering direction across the facility.

The role leads development and optimization of CCA processes, establishes long-range process capability goals, and oversees process documentation, standards, process monitoring, and major technical changes. It collaborates with Design Engineering, Quality, Operations, and Program Management to address complex manufacturing challenges and support New Product Introduction. The Principal Process Engineer also leads equipment and technology implementation, mentors engineers at several levels, delivers training, and works with Operations and Manufacturing Engineering on MES/ERP capabilities for process control and traceability.

Requirements

• Bachelor's degree in Mechanical, Electrical, Manufacturing Engineering, or a related field.
• 10+ years of experience in electronics manufacturing and CCA process engineering.
• Deep expertise in SMT, soldering, inspection technologies, and high-reliability electronics manufacturing.
• Strong knowledge of IPC-A-610, J-STD-001, and aerospace/defense manufacturing requirements.
• Proven experience leading multidisciplinary engineering projects and driving high-impact technical initiatives.
• Hands-on experience with SMT platforms (e.g., FUJI), AOI/SPI systems (e.g., Koh Young), wash processes, conformal coating, and ruggedization.
• Advanced capability in SPC, data analysis, Six Sigma methodologies, and process validation.
• Strong collaboration skills and ability to influence engineering and manufacturing decisions across teams.
• Must be eligible to obtain and maintain a U.S. Government security clearance.

Nice To Haves

• Master's degree.
• Experience supporting New Product Introduction (NPI) and establishing new manufacturing capabilities.
• Expertise with CAD tools for process/fixture design and manufacturing simulation.
• Demonstrated success implementing advanced automation and digital manufacturing solutions.
• Ability to lead multiple technical projects simultaneously with minimal supervision.
• Strong communication skills for guiding teams and presenting complex technical information.
• Basic understanding of APQP (Advanced Product Quality Planning) principles.
• Working knowledge of DMAIC methodology (Define-Measure-Analyze-Improve-Control).
• Familiarity with the PDCA (Plan-Do-Check-Act) continuous improvement cycle.

Responsibilities

• Lead development, implementation, and optimization of advanced CCA manufacturing processes, including SMT, wave/selective soldering, bonding/staking, conformal coating, and ruggedization.
• Establish long-range process capability goals and technical strategies to improve manufacturing robustness, automation, and efficiency.
• Serve as the technical authority for CCA processing documentation, work instructions, and standards at the Center of Excellence.
• Ensure CCA processes meet IPC-A-610, J-STD-001, and applicable MIL requirements.
• Lead root cause investigations into complex or high-impact quality challenges and coordinate cross-functional corrective actions.
• Oversee advanced SPC, data analytics, and process monitoring for critical manufacturing steps.
• Lead multidisciplinary technical projects to improve yield, manufacturability, cost, automation, and defect reduction.
• Partner with Design Engineering, Quality, Operations, and Program Management to resolve complex manufacturing challenges and support NPI.
• Lead implementation of new equipment, inspection systems, and automation technologies.
• Evaluate and integrate emerging manufacturing technologies, including SMT platforms, AOI/SPI systems, and automation solutions.
• Drive digital manufacturing enhancements, process modeling, and capability studies.
• Provide technical mentorship to Senior, Mid-level, and Junior Process Engineers.
• Review and approve major process changes, validation plans, and engineering documentation.
• Deliver training on advanced electronics manufacturing processes, inspection methods, soldering best practices, and thermal profiling.
• Develop and maintain advanced process metrics using data-driven approaches.
• Partner with Operations and Manufacturing Engineering to enhance MES/ERP capabilities supporting process control and traceability.

Benefits

• Most locations offer a 9/80 schedule, providing every other Friday off.
• Competitive compensation and a 401(k) program.
• Medical, dental, vision, and disability coverage with qualified wellness discounts.
• Basic Life Insurance and additional Life and AD&D insurance options.
• Flexible Vacation and PTO.
• Paid Parental Leave.
• Employee Referral Program.
• Voluntary benefits, including Long-Term Care, Legal, Identity Theft, and Pet Insurance.
• Voluntary Tricare Supplement available for military retirees.

What This Job Offers

• Job Type: Full-time
• Career Level: Principal