Senior Manufacturing Engineer, DFMA - Composites

Mach Industries•Huntington Beach, CA

14h

About The Position

Mach Industries is hiring a Senior Manufacturing Engineer focused on composites design for high-rate production. The engineer will review composite designs at part, assembly, and system levels from concept through production release, and lead research and development on materials, hardware, and processes. The role includes designing experiments, building test articles, working with suppliers, and transitioning proven methods into production. The engineer will own Mach’s Composites DFMA guide and establish production-oriented design rules and standards for liquid composite molding processes, preforming, injection, curing, demolding, trimming, drilling, and inspection. The role will advise on vehicle architecture and early material and process selection, drive part consolidation and error-proofing, set design-gate sign-off criteria, and track program metrics including cycle time, material utilization, yield, scrap, and cost. The position will develop trade studies and should-cost, production-rate, and material-utilization models to inform process selection, make-versus-buy decisions, investment, and supplier negotiations. It will prepare technical data packages for outsourced production, assess and validate supplier capabilities, and bridge automotive launch practices with aerospace and defense quality requirements. The engineer will lead a composites R&D roadmap focused on cycle time, automation, and scrap reduction; plan and conduct designed experiments; test and analyze coupons and test articles; and publish findings. The role also includes tooling feasibility and buyoff, supplier and tool-maker assessments, participation in design and process FMEAs, maintaining a library of failure modes and controls, and mentoring engineers while helping build Mach’s DFMA function. The position requires availability for extended hours and weekends as needed. Applicants must meet the stated U.S. export-control eligibility requirements or be eligible to obtain required authorizations. Compensation is listed at $140,000–$180,000 USD for the Senior Engineer level, with potential equity and benefits described in the posting.

Requirements

BS in Mechanical, Materials, or Chemical Engineering, or equivalent experience.
At least 7 years of composite manufacturing, process, or design engineering experience 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.
Experience launching a high-rate composite part or production line, in-house or at an outside manufacturer, including tooling, equipment, run-at-rate, and ramp.
Experience with draping and mold-filling simulation, such as PAM-RTM or similar, and composite design tools such as CATIA Composites Design or Fibersim.
Track record of writing design standards, guides, or process specifications.
Strong manufacturing and industrial engineering fundamentals, including 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.
Proficiency in 3D CAD such as NX, CATIA, SolidWorks, or similar.
Available to work extended hours and weekends as needed.
Must be a U.S. citizen or national, lawful permanent resident, qualifying refugee or asylee, or eligible to obtain required U.S. Department of State authorizations for applicable export-controlled information.

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, such as HP-RTM or compression-molded structural parts.
Experience at a composites equipment maker or automation integrator, including presses, injection systems, AFP/ATL machines, or preforming cells.
Familiarity with automotive launch practices (APQP, PPAP) and aerospace quality systems (AS9100, AS9102).
Experience with formal DFMA methods such as Boothroyd Dewhurst, should-cost modeling, and value engineering programs with measured savings.
Lean or Six Sigma certification.

Responsibilities

Own, write, publish, and maintain Mach’s Composites DFMA guide, including design rules, preferred materials and processes, process tolerances, worked examples, and review checklists.
Develop design rules for LCM processes, including preform design, gate/vent/flow-path design, molded part geometry, features and inserts, and net-shape versus trimmed edges.
Set rate-capable standards for preforming, injection, cure, demold, trim, drill, and inspection in automated cells.
Define DFMA sign-off criteria for design gates, verify that parts fit their target production lines, and hold programs to those criteria.
Set and track program DFMA metrics such as part count, cycle time, material utilization, first-pass yield, scrap rate, and cost.
Advise on vehicle architecture and early material and process choices; match parts to suitable high-rate processes and line capabilities.
Drive part consolidation using molded-in features and co-molded assemblies, and define composites poka-yoke standards.
Lead value engineering on released designs and support trade studies and make-versus-buy decisions.
Develop should-cost, production-rate, and material-utilization models to evaluate design choices, process selection, costs, schedules, quality, and capital investment.
Use should-cost models to support Supply Chain partner selection and negotiations.
Find and assess high-volume composites manufacturers and validate their capabilities, capacity, and quality systems.
Build composites technical data packages, including models, drawings, material and process specifications, key characteristics, acceptance criteria, and inspection plans.
Bridge automotive launch practices such as APQP and PPAP with aerospace and defense quality requirements such as AS9100 and AS9102.
Set and run a composites R&D roadmap focused on shorter cycle times, increased automation, and reduced 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, and closed-loop cure monitoring.
Plan and run designed experiments; build coupons and test articles, test to failure, analyze results statistically, and publish findings.
Own tooling feasibility, design reviews, and buyoff for matched-metal molds, preform tools, and AFP/ATL tools built for Mach or partners.
Assess tool suppliers on site and encourage best practices and lower investment.
Contribute composites expertise to DFMEAs and PFMEAs, and maintain a library of failure modes and proven controls.
Mentor engineers and help build Mach’s DFMA function.