Senior Manufacturing Engineer - Space Technologies

AeroVironment•Albuquerque, NM

About The Position

The Senior Manufacturing and Process Engineer develops, implements, qualifies, optimizes, and sustains manufacturing processes for precision optical and electromechanical systems used in space applications. Products include fast steering mirrors, delicate optical components, optical bench assemblies, and integrated optical systems requiring controlled assembly, alignment, and performance verification. This role is a technical lead within Manufacturing Engineering, partnering with Design, Optical, Systems, Quality, Supply Chain, Operations, and Test Engineering to translate product requirements into repeatable production processes. The engineer leads process development and continuous improvement, supports research and development and new product introduction, resolves complex production issues, and mentors engineers and manufacturing personnel while improving quality, yield, cost, safety, and delivery. The position may involve work in office, engineering laboratory, cleanroom, and manufacturing environments. Occasional off-shift or extended-hours production support and travel may be required. The role requires U.S. citizenship and the ability to obtain and maintain a Department of Defense security clearance. The position also involves access to ITAR- and/or EAR-controlled information, subject to applicable export-control eligibility requirements.

Requirements

Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Optical Engineering, Electrical Engineering, Industrial Engineering, or a related technical field.
Typically 3–7 years of relevant manufacturing or process engineering experience, or an equivalent combination of education and experience.
Demonstrated experience developing and sustaining processes for precision optical, optomechanical, or complex electromechanical products and assemblies.
Hands-on experience with delicate component handling and precision assembly, alignment, metrology, or performance testing.
Experience with new product introduction, production transition, design for manufacturability, and cross-functional technical projects.
Working knowledge of controlled bonding, cleanliness, contamination prevention, precision tooling, and process verification applicable to optical hardware.
Strong knowledge of root-cause analysis, corrective action, process capability, and continuous-improvement methods.
Experience creating and maintaining manufacturing documentation and product traceability in a controlled environment.
Ability to interpret engineering drawings, GD&T, specifications, bills of material, and test requirements.
Strong analytical, problem-solving, communication, and organizational skills, and ability to work effectively with engineering, operations, quality, supply chain, and external suppliers.
Proficiency with Microsoft Office or equivalent productivity tools.
U.S. citizenship is required.
Ability to obtain and maintain a Department of Defense security clearance.
Ability to work in office, engineering laboratory, cleanroom, and manufacturing environments; wear required personal protective equipment, cleanroom garments, and ESD protection; and perform or support precision assembly and inspection using microscopes, optical instruments, and production equipment, with or without reasonable accommodation.
Ability to occasionally lift, carry, or manipulate materials and equipment within applicable safety limits, and to stand, walk, bend, and reach as required, with or without reasonable accommodation.
Ability to support occasional off-shift or extended-hours production activities.

Nice To Haves

Experience manufacturing space-flight optical hardware, fast steering mirrors, beam steering mechanisms, optical payloads, or precision pointing systems.
Experience with optical alignment and metrology tools such as interferometers, autocollimators, alignment telescopes, coordinate measurement systems, and optical power or beam measurement instruments.
Experience with fast steering mirror actuator and sensor integration, flexure assemblies, dynamic characterization, and collaboration with controls and test teams.
Familiarity with thermal vacuum, vibration, shock, and environmental stress screening, including performance verification and alignment retention across test exposures.
Experience with cleanroom operations, optical cleaning, adhesive qualification, cure verification, and material selection for contamination-sensitive or vacuum applications.
Experience with ERP, MRP, MES, PLM, or manufacturing document-control systems, including Factory Logix or comparable platforms.
Experience with CAD and designing precision assembly, alignment, handling, and test fixtures.
Experience with automation, automated data collection, test scripting, or manufacturing systems integration.
Experience in aerospace, defense, or another highly regulated manufacturing environment; familiarity with AS9100, ISO 9001, and applicable IPC workmanship requirements.

Responsibilities

Develop, document, validate, and sustain assembly, integration, alignment, and test processes for space optical systems, precision optomechanical assemblies, and fast steering mirrors.
Lead manufacturing readiness from prototype development through design transfer, qualification builds, and production transition; identify process maturity gaps and implement plans to close them.
Review designs for manufacturability, assembly, alignment access, inspection, testability, serviceability, cost, tolerance stacks, datum strategies, and sensitivity to handling and assembly variation.
Establish methods for handling, cleaning, protecting, packaging, and storing delicate optics and coated surfaces, including appropriate contamination, FOD, and ESD controls.
Develop controlled bonding and curing processes, including surface preparation, adhesive mixing and dispensing, bond-line control, fixturing, shimming, cure parameters, and verification methods.
Develop fast steering mirror assembly processes covering mirrors, mounts, flexures, actuators, coils, sensors, wiring, and cables; control polarity, cable routing, keep-out zones, flexure protection, and handling during adjustment.
Partner with Optical and Test Engineering to establish alignment sequences, metrology setups, reference datums, adjustment methods, and optical and electromechanical acceptance criteria.
Develop repeatable measurement and test methods for applicable requirements such as mirror flatness, surface figure, wavefront error, boresight, line-of-sight stability, range of motion, pointing accuracy, repeatability, and dynamic response.
Create and maintain controlled work instructions, process specifications, standard operating procedures, process flow diagrams, travelers, assembly aids, bills of material, routings, and tooling requirements.
Design or coordinate precision fixtures, alignment tooling, optical handling aids, gauges, and test equipment; ensure production aids protect hardware and support repeatable assembly and inspection.
Support equipment selection, installation and operational qualification, performance qualification where required, calibration, measurement-system assessment, and preventive maintenance planning.
Establish process parameters, in-process inspection points, acceptance criteria, traceability requirements, and production controls; maintain PFMEAs and associated control plans.
Investigate nonconformances, optical performance degradation, bond failures, alignment drift, yield losses, and process escapes; lead structured root-cause analysis and verify corrective-action effectiveness.
Analyze process and test data to identify variation, constraints, rework drivers, and capacity needs; apply Lean Manufacturing, Six Sigma, and other appropriate improvement methods.
Support first article inspections, capability studies, process validation, qualification testing, and production readiness reviews; assess alignment and functional performance before and after environmental testing as required.
Partner with Quality Engineering on material review board activities, inspection methods, corrective actions, and disposition support; evaluate how rework methods affect optical surfaces, bonds, and alignment.
Support supplier development and qualification for optics, coatings, precision-machined hardware, adhesives, electromechanical components, and outsourced processes; translate requirements into receiving and acceptance controls.
Assess manufacturing impacts of design, material, chemistry, tooling, software, and process changes; define supporting data, requalification needs, documentation updates, and implementation tasks.
Develop training using mock-ups, representative hardware, and practical demonstrations; mentor Manufacturing/Process Engineers I and II and train technicians in optical handling, assembly, alignment, and process discipline.
Participate in design reviews, risk assessments, production readiness reviews, and program reviews; communicate manufacturing risks, recovery plans, and readiness status.
Ensure manufacturing processes meet applicable engineering, quality, safety, environmental, and program requirements; support urgent production troubleshooting and perform other assigned duties.