Sr. Design for Manufacturing (DFM) Engineer
About The Position
The Sr. Design for Manufacturing (DFM) Engineer owns the manufacturability of magniX electric propulsion hardware as it transitions from development to rate production. This is a design role focused on reducing time, labor, scrap, and unit cost through design changes. Initial priorities include redesigning assembly interfaces that drive excessive build time and improving machinability of housings, end bells, shafts, and structural components through simplified features, optimized tolerances, and reduced setups. Long term, this role will establish DFM as a core design-review gate, define producibility standards, and partner with Manufacturing, Quality, Supply Chain, and assembly floor. This role is suited for an experienced engineer who can independently drive impactful design improvements with minimal onboarding.
Requirements
- B.S. in Mechanical Engineering or related field
- 7+ years of design engineering experience with DFM/DFA ownership for precision electromechanical or rotating hardware
- Proven record of reducing manufacturing cycle time, labor, scrap, or cost through design improvements
- Strong knowledge of CNC machining, grinding, setups, workholding, tooling, and manufacturing cost drivers
- Proficiency in GD&T (ASME Y14.5) and tolerance stack-up analysis
- Experience with CAD modeling and production drawing release experience; Solidworks preferred
- Working knowledge of assembly processes, fabrication methods, and quality assurance techniques
- Experience working directly with machinists, technicians and suppliers
Nice To Haves
- DFM experience with electric machines: rotors, stators, laminations, magnets, windings, shafts, bearings, housings, and potting or encapsulation
- Experience transitioning a product from prototype or low-rate build to rate production
- Experience with press and shrink fits, heat-assisted assembly, and the balance and runout requirements of high-speed rotating assemblies
- Familiarity with castings, forgings, and near-net-shape processes and the associated supplier base.
- CAM experience or hands-on machining background
- Experience designing within AS9100 quality system requirements and familiarity with the FAA regulatory environment and certification impact of design changes
- Six Sigma, Lean Manufacturing, or Design for Six Sigma training
Responsibilities
- Own design for manufacturing and assembly (DFM/DFA) across electric propulsion products, from detailed parts through full assemblies
- Redesign assembly interfaces and component designs to reduce build time, cost, and production complexity, prioritizing opportunities by impact to cycle time, labor, scrap, tooling investment, and unit cost
- Perform tolerance stack-up analysis and apply GD&T (ASME Y14.5) to balance manufacturability, cost, and performance requirements
- Lead DFM reviews and maintain design standards, checklists, best practices, and production-readiness criteria
- Evaluate and recommend process and material changes — castings, near-net-shape, additive, alternative joining — supported by business case analysis
- Partner with suppliers, machine shops, and internal teams (Manufacturing, Tool Design, Quality, Supply Chain, Test) to resolve producibility issues and carry design changes through to production release
Benefits
- 100% company-paid premiums for medical, dental, and vision insurance (for employees & dependents).
- 4 weeks paid vacation + 1-week annual end-of-year shutdown, sick time, and 11 paid holidays.
- 401K retirement plan with industry leading 9.5% company contribution.
- Company paid Life insurance, AD&D, Short-Term and Long-Term disability insurance
- Catered lunches and quarterly company fun-day events!
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What This Job Offers
Job Type
Full-time
Career Level
Senior
