Senior DFM Engineer

Powell Industries•Houston, TX

About The Position

Powell Research and Development is hiring a Senior Design for Manufacture (DFM) Engineer in Southeast Houston. This role is intentionally designed to recognize either formal engineering education with experience OR extensive hands-on CNC machining expertise as equally valuable pathways to success. As a Senior DFM Engineer, you will be a core member of the Research and Development Team, working alongside New Product Development Engineers, Manufacturing Engineers, and production teams to ensure new designs are manufactural, cost-effective, and production-ready. This position bridges design intent and shop-floor reality and plays a critical role in scaling designs from prototype to full production. This position does not allow for sponsorship support.

Requirements

Strong understanding of DFM/DFA principles
Solid knowledge of sheet metal design, including self-fixturing concepts
Ability to interpret and influence CAD models and engineering drawings (Autodesk Inventor experience preferred; CAD proficiency required regardless of pathway)
Working knowledge of CNC programming strategies (e.g., Mastercam or similar CAM systems)
Strong mechanical aptitude with understanding of:
Pneumatic, hydraulic, and servo systems
Machine controls and automation
Familiarity with statistical test procedures and corrective action techniques
Strong problem-solving and analytical skills
Effective written and verbal communication skills, especially between engineering and shop-floor teams
Ability to manage multiple priorities and drive work to completion
Self-motivated, adaptable, and comfortable leading change

Responsibilities

Collaborate with cross-functional engineering, manufacturing, and machining teams to ensure robust DFM/DFA/DFX, throughout the product lifecycle.
Review parts and assemblies with a strong focus on machinability, tolerancing, fixturing, tooling access, and assembly efficiency.
Identify manufacturability, machining, and assembly risks early and provide clear, actionable design recommendations.
Translate design intent into practical, repeatable manufacturing solutions, informed by real-world machining capability.
Ensure product manufacturing and assembly requirements are clearly understood by production teams.
Support new product development by evaluating and improving machining methods, tooling strategies, fixtures, and work holding concepts.
Improve manufacturing efficiency by helping to analyze and plan workflow, space requirements, and equipment layout.
Assures product and process quality by helping to design testing methods; testing finished- product and process capabilities; establishing standards; confirming manufacturing processes.
Provides upfront input into prototype and production designs, including machining time, labor estimates, tooling cost, and material selection.
Support development of work instructions, machining standards, and best practices.
Serve as a technical resource for manufacturability and machining feasibility questions.
Train and support manufacturing and assembly personnel as needed.
Contributes to continuous improvement initiatives and cross-functional problem solving.