Senior Staff Manufacturing Engineer

Boston Dynamics•Waltham, MA

3d•$135,000 - $170,000

About The Position

Boston Dynamics is seeking a Senior Staff Manufacturing Engineer to support the Atlas program, helping transform research prototypes into reliable, scalable systems for manufacturing and field deployment. The role focuses on optimizing and scaling low-volume production processes, assembly workflows, and custom tooling for assembly, test, and integration of the humanoid robot. The engineer will work closely with Hardware Engineering, Prototype Operations, Systems Engineering, Behavior, and Software teams, and will interface with parent company Hyundai Motor Group to leverage its automotive manufacturing expertise. The role requires expert technical experience in end-to-end process implementation and production-system and value-stream design. The engineer will oversee automation equipment and the design and implementation of fixtures, tools, and jigs to ensure repeatable processes and product quality. This position also provides hands-on support for prototype builds and helps bridge product design and manufacturing execution.

Requirements

Bachelor’s degree in Manufacturing, Mechanical, Industrial, or Electrical Engineering, or a related field.
At least 8–15 years of relevant experience in process engineering, process development, or advanced manufacturing.
Expert-level proficiency in CAD software such as SolidWorks, CATIA, or similar for tool and fixture design and engineering drawing review.
Proven track record collaborating with design teams on DFM/DFA to support manufacturable and serviceable product designs.
Hands-on experience developing and validating custom tooling, jigs, and fixtures for precision mechanical assembly.
Experience developing and validating custom automation equipment for precision mechanical assembly and process efficiency.
Experience writing clear, concise, detailed work instructions, SOPs, and training materials for assembly technicians.
Familiarity with precision assembly techniques, including alignment, shimming, fastening, sealing, and torque control for complex assemblies.
Experience in prototype, low-volume, or high-mix production environments and adapting processes as product designs evolve.
Strong understanding of GD&T and its application in design and inspection.
Demonstrated experience applying Lean Manufacturing, Six Sigma, and root cause analysis to improve processes.
Strong problem-solving skills and ability to troubleshoot complex mechanical and electromechanical assemblies.
Ability to work in cross-functional teams while balancing technical, schedule, and cost considerations in a fast-paced environment.
Strong communication skills and ability to present technical concepts and influence stakeholders across engineering, operations, and leadership.
Experience supporting on-site prototype builds and providing direct manufacturing-floor support.
Hands-on experience with additive manufacturing, rapid prototyping, machining such as milling and turning, and fabrication such as welding, grinding, and bending for fixture development.
Eligible to work in the United States; visa sponsorship is not available.

Nice To Haves

Master’s degree or PhD.
Experience developing and documenting CNC machining processes for novel materials and manufacturing methods, including specialized gear manufacturing.
Experience supporting humanoid or robotic development programs.
Familiarity with precision motion systems, actuators, and advanced sensors.
Experience with PLM systems for engineering change control and manufacturing documentation management.
Experience with MES for production-floor management, process control, and visual management.
Background working with external design firms, contract manufacturers, or suppliers on tool and fixture development.
Experience in a research-to-product transition environment where designs and processes evolve rapidly.
TWI Job Instruction and/or Job Methods certification.

Responsibilities

Develop, optimize, and implement rate-production processes and assembly workflows for Atlas, from prototype through low-volume production, while preparing for future production needs.
Design and implement production-system tools, including material-flow diagrams, value-stream maps, floor layouts, and automation integrations.
Collaborate with Hardware Engineering to provide DFM/DFA input throughout product development and improve manufacturability and serviceability.
Design, fabricate, and validate custom fixtures, tools, and jigs for mechanical assembly, precision alignment, and electric motor and actuator testing.
Define assembly sequences, work instructions, and process documentation, including SOPs, visual aids, and training materials for assembly technicians.
Provide hands-on support for prototype builds, troubleshoot assembly issues, identify root causes, and drive corrective actions to improve processes and product designs.
Implement process controls to ensure build quality, dimensional accuracy, and alignment with product performance requirements.
Develop and implement inspection and test processes, including first article inspections, in-process quality checks, and final acceptance criteria.
Collaborate with Supply Chain to align external fabrication and supplier processes with internal manufacturing requirements and quality standards.
Lead continuous improvement initiatives using Lean Manufacturing and Six Sigma methods to improve efficiency, reduce cycle times, and increase yield.
Drive tooling and equipment validation, qualify custom fixtures and tools for production, and perform capability studies where needed.