Staff Hardware Engineer – DFx (Manufacturing, Test & Tooling)

GM•Warren, MI

7d•$159,400 - $245,000•Hybrid

About The Position

General Motors is leading the transformation of the automotive industry through electrification, central compute, and autonomous technologies. We are building a high-energy team of Senior DFx (Design for Manufacturing, Test, and Tooling) engineers to serve as the critical link between internal design teams and contract manufacturers for next-generation ECUs. This team will establish and drive DFx processes for in-house GM designs, ensuring strong alignment between design and manufacturing. They will bring early insight into manufacturing, assembly, testing, and tooling—embedding best practices, lessons learned, and critical requirements into module development. We are seeking a high-performing Staff DFx Engineer to represent the voice of manufacturing, testing, and tooling across GM’s electronics development. This role focuses on circuit board design, population, test, and assembly, working closely with both internal design teams and external manufacturing partners. You will lead DFx strategy and execution for electrical controllers supporting GM’s Software Defined Vehicle (SDV) architecture, while building strong, cross-functional partnerships to ensure successful product delivery.

Requirements

BS in Electrical or Mechanical Engineering or equivalent engineering degree
7+ years in-plant electronic control module manufacturing experience leading a cross functional team of Design/Manufacturing engineers for best in class DFM and DFT designs
Collaborative, team centered experience which leads to on-time delivery of quality products
Exceptional collaboration and teamwork skills; demonstrated ability for working across functional and organizational boundaries.
Proficiency in 3D CAD modeling, 2D drawings, schematic designs, test SW development, tolerance analysis, design for manufacturability, and assembly.
Strong analytical skills and engineering fundamentals in manufacturing, testing, tooling of automotive electronic modules.
Hands-on experience engaging with electronics manufacturers.

Nice To Haves

Master’s degree/PhD in Electrical or Mechanical Engineering
Mechanical design of PCBAs, computers, or automotive electronics
Experience establishing a DFx organization within an automotive OEM.
Industry leading expertise with aspects of manufacturing including: Designed SMT placement equipment, solder reflow equipment, Developed AOI, SPI, Assembly line transfer equipment.

Responsibilities

Work with cross functional teams for the selection of test point location, in-circuit board coverage, functional test requirements from design teams, and programming requirements from design/CM teams.
Expertise in process from bare board to fully populated, soldered, tested PCB
Expertise in Solder Paste/Stencil process and materials, SPI Solder process Inspection, Acceptance Criteria, SMD placement, line loading, AOI, Reflow profile, Intermetallic and PCB surface finish
Perform design calculations, GD&T and tolerance stacks required for tooling and test fixtures
Create 3D CAD, 2D CAD & lead CAD reviews with stakeholders.
Develop analysis and test plans for new designs, perform proof of concept tests and analysis.
Lead prototyping and testing, analyze test data, and make necessary adjustments to manufacturing process/materials, in-plant testing and tooling designs.
Work with electrical engineers and PCBA designers to integrate components into test fixtures for in-circuit, functional, and in-process SW programming.
Build partnerships with functional peers internally within GM and externally at CM suppliers to align on ECU design per development cycles.
Develop virtualization technologies that help accelerate and de-risk product development.
Communicate Contract Manufacturing progress and risks to stakeholders and customers.
Drive Cross CM strategies for commonality within GM’s in-house designs.
Solid organizational skills and the ability to manage multiple projects simultaneously.