Senior Manufacturing Engineer, DFMA - Composites

Mach Industries•Huntington Beach, CA

5h•$140,000 - $180,000•Onsite

About The Position

As Senior Manufacturing Engineer, Composites, you'll be Mach's go-to expert on designing composite structures for high-rate production. You'll review designs at the part, assembly and system level from concept through production release. You'll also push the field forward through research and development (R&D) on new materials, hardware and processes. You'll design experiments, build test articles, partner with suppliers and move what works into production. Examples include snap-cure resins, net-shape automated preforming, and closed-loop process control that cut cycle time and scrap.

Requirements

BS in Mechanical, Materials or Chemical Engineering, or equivalent experience.
7+ years in composite manufacturing, process or design engineering for high-rate production.
Hands-on experience with at least one of: HP-RTM or other LCM processes, AFP / ATL, or automated preforming or ply pick-and-place.
Launched a high-rate composite part or production line, in-house or at an outside manufacturer. The launch should have included tooling, equipment, run-at-rate and ramp.
Experience with draping and mold-filling simulation (for example, PAM-RTM or similar) and composite design tools (CATIA Composites Design, Fibersim or similar).
A track record of writing design standards, guides or process specs.
Strong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics and ROI.
Working knowledge of GD&T (ASME Y14.5), tolerance stack-ups and DVA.
Skilled in 3D CAD (NX, CATIA, SolidWorks or similar).

Nice To Haves

MS or PhD in Materials Science, Aerospace Engineering or a related field.
High-volume automotive composites experience at an OEM or Tier 1 supplier, for example HP-RTM or compression-molded structural parts.
Experience at a composites equipment maker or automation integrator (presses, injection systems, AFP and ATL machines, or preforming cells).
Familiarity with automotive launch practices (APQP, PPAP) and aerospace quality systems (AS9100, AS9102).
Formal DFMA methods (for example, Boothroyd Dewhurst), should-cost modeling, and value engineering programs with measured savings.
Lean or Six Sigma certification.

Responsibilities

Own the Composites DFMA guide: design rules for each high-rate process, with reasoning and data behind them; preferred materials, processes and tooling approaches by part type and volume; standard features and the tolerances each process can hold; worked examples and review checklists.
Write design rules for LCM (RTM, HP-RTM, C-RTM, wet compression molding): preform design: drapability, fiber shear limits, binder, and fiber volume control; gate, vent and flow-path design, checked with draping and mold-filling simulation; wall thickness and transitions, radii, draft, molded-in features and inserts; net-shape edges vs. trimmed edges.
Set rate-capable standards for preforming, injection, cure, demold, trim, drill and inspection in automated cells.
Define the DFMA sign-off criteria for design gates, including a check that each part fits its target production line, and hold programs to them.
Set and track DFMA metrics for each program, such as part count, cycle time, material utilization, first-pass yield, scrap rate and cost.
Shape designs early: Advise vehicle architecture, material and process choices before designs lock. Match each part to the right high-rate process early, and design it to that line's capability. Drive part consolidation through molded-in features and co-molded assemblies. Define composites poka-yoke standards, for example asymmetric locators, in-line vision checks of fiber orientation and of tow and ply placement, insert-presence sensing and mold-close interlocks, indexing features for trim and drill, asymmetric hole patterns on mating parts.
Lead value engineering on released designs: challenge assumptions and take out cost.
Enable trade studies and make vs. buy: Develop the data, cost models and decision criteria for metal vs. composite structures at rate; process selection, such as HP-RTM vs. compression molding vs. AFP or ATL; building in-house vs. outsourcing to a high-volume composites manufacturer. Build should-cost, rate and material-utilization models that show how design choices affect cycle time, cost, schedule, quality and capital investment (presses, injection equipment, AFP and ATL machines, preforming cells and tooling). Use should-cost models to support Supply Chain in partner selection and negotiations.
Prepare designs for outsourcing and deploy partner lines: Find and assess high-volume composites manufacturers, including automotive and industrial suppliers. Validate capability, capacity, quality. Build composites technical data packages: models and drawings, material and process specs, key characteristics, acceptance criteria and inspection plans. Bridge automotive launch practices (APQP, PPAP) with aerospace and defense quality requirements (AS9100, AS9102 first article inspection).
Lead R&D: Set and run a composites R&D roadmap aimed at shorter cycle times, more automation and less scrap. Lead R&D on snap-cure and fast-cure resins; automated and net-shape preforming; dry-fiber placement for infusion; thermoplastic tape placement and stamping; cure monitoring with closed-loop process control. Plan and run designed experiments (DOE). Build coupons and test articles, test to failure, analyze results with sound statistics, and publish findings.
Support production and suppliers: Own tooling feasibility, design reviews and buyoff for matched-metal molds, preform tools, and AFP and ATL tools, whether built for Mach or for a partner. Assess tool suppliers on site, and push them to best practices and lower investment. Bring composites expertise to design and process FMEAs (DFMEAs and PFMEAs). Maintain a library of known failure modes and proven controls.
Mentor engineers and help build Mach's DFMA function.