Senior DFx Engineer

Viasat, Inc.•Carlsbad, CA

1d•Hybrid

About The Position

We are looking for a Senior DFx Engineer to join our Operations teams! In this role, you will use your advanced knowledge of Surface Mount Technology (SMT) processes and DFx principles to improve product readiness for production across all development phases. You will play a critical role in ensuring robust PWA designs and SMT assembly workflows for sophisticated PWAs, driving higher yields, lower costs, and improved reliability.

Requirements

BS degree in Engineering or equivalent experience.
10+ years of proven experience in high-mix, high-density SMT assembly environments, including fine-pitch and BGA components.
Proven teammate with strong networking and communication abilities, capable of influencing decisions and working seamlessly across diverse technical teams.
Ability to prioritize tasks, maintain attention to detail, and manage time effectively to handle multiple responsibilities concurrently.
Strong understanding of IPC-A-610, IPC-7351, J-STD-001, and SMT-specific inspection criteria.
Extensive experience applying design-for-manufacturability principles to PWA architecture and assembly workflows, reducing cost and improving reliability.
Skilled in reflow profiling, stencil design optimization, solder paste selection, and thermal management for complex assemblies.
Familiarity with SMT process simulation and analysis tools (Valor, Minitab) and inspection systems (AOI, AXI).
Ability to identify root causes of SMT defects and implement corrective actions quickly. Experienced in using PFMEA and DFMEA evaluations to drive producibility, quality, cost, and reliability in product development.
U.S. Citizenship required.
Ability to travel (up to 20%) for on-site process validation and technical support.

Nice To Haves

Skilled in driving process evaluations and validations with contract manufacturers, ensuring robust manufacturing practices and proactive failure prevention.
Strong understanding of PWA assembly workflows and inspection processes, including screen printing, SPI, pick-and-place, reflow, AOI, AXI, FPT, and ICT.
Experience with high-mix, high-density PWA designs and assembly.
Space hardware experience.
Familiarity with Minitab, JIRA, Mentor Graphics, Valor, Agile, Solid-Works, and Oracle.
Electro-mechanical design and assembly experience.
Available to work on-site at least three days per week in a hybrid schedule (Carlsbad, CA, Tempe, AZ).
Active DoD Secret clearance or ability to obtain when administratively feasible

Responsibilities

Participate in design reviews to ensure component placement, pad design, and stencil aperture meet manufacturability standards.
Provide feedback to design engineers on layout and thermal considerations.
Run small-scale experiments (DoEs) to validate SMT parameters like solder paste type, stencil thickness, and reflow profiles.
Perform CpK analysis and Gage R&R studies to confirm process capability and measurement accuracy.
Work with the EMS and PE to establish, monitor, and optimize SMT assembly steps: screen printing, SPI, pick-and-place, reflow profiling, AOI, AXI, and selective soldering.
Review production data and address any anomalies in SMT workflows or design related issues that affect yield.
Communicate with contract manufacturers to align on SMT standard methodologies and resolve process issues.
Support NPI builds and solve assembly challenges with design and manufacturing teams.
Drive cost-reduction and yield-improvement initiatives at supplier sites.
Serve as “the” technical resource to interdisciplinary teams, councils, and management.
Provide technical leadership and mentoring to junior engineers.
Communicate progress and risks to stakeholders effectively.
Investigate defects such as tombstoning, solder voids, or insufficient wetting using SEM, X-ray, and optical microscopy.
Document findings and implement corrective actions.
Maintain DFx checklists, processes, and best-practice guidelines.
Engage with quality on PFMEA/DFMEA engagements for producibility enhancement opportunities on future designs.
Find opportunities for automation and inspection enhancements.
Monitor SMT yield, process capability, and improvement initiatives.
Maintain clear records of validation results and corrective actions.
Provide build readiness updates using PRS, Producibility Reports, and updates at critical design reviews.

Benefits

Additional cash or stock incentives may be provided as part of the compensation package, in addition to a range of medical, financial, and/or other benefits, dependent on the position offered.
Learn more about Viasat’s comprehensive benefit offerings that are focused on your holistic health and wellness at https://careers.viasat.com/benefits.

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