Lead Manufacturing Engineer, DFMA - Tooling Design

About Mach Industries

Founded in 2023, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 350 employees, we operate with startup agility and ambition.

Our vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security.

The Role

As Lead Manufacturing Engineer, Tooling Design, you'll be Mach's go-to expert on two things: how we design tooling, and how parts are designed so automation can handle, locate and assemble them. You'll push the field forward through research and development (R&D) on new materials, hardware and processes. You'll design experiments, build test articles, partner with suppliers and move what works into production. This is a hands-on technical leadership role with direct reports.

Key Responsibilities

Own the Tooling and Design-for-Automation guide

• Write, publish and maintain Mach's Tooling and Design-for-Automation guide. It should cover:
• design rules, with the reasoning and test data behind them
• preferred tooling components, materials and automation approaches
• standard locating features and tolerances
• worked examples and review checklists
• Write tooling standards: datum and locating strategy, modular fixture components, clamping, materials and documentation.
• Write design-for-automation rules for parts: gripping and locating features, part presentation and feeder compatibility, robot and tool access
• Set metrology and tooling verification standards (laser tracker, CMM, vision), and oversee checking fixtures and gauges.
• Define the DFMA sign-off criteria for design gates and hold programs to them.
• Set and track DFMA metrics for each program, such as part count, assembly time, automation rate, tooling cost and lead time, and first-pass yield.
• Keep the guide current with test results, production lessons and supplier input. Train design and manufacturing engineers to apply it.

Shape designs early

• Review vehicle architecture and material choices at concept, before designs lock. Focus on datums, locating and automated handling.
• Run DFMA studies at the part, assembly and system level, and give design teams specific feedback backed by data.
• Lead static and kinematic assembly studies (virtual builds) to check robot reach, tool access, clearance and install paths before hardware exists.
• Drive content reduction, simpler assembly, build-in-quality and ergonomic access. Push for wider tolerances where performance allows, and for features that suit automation.
• Lead value engineering on released designs: challenge assumptions and take out cost.

Enable trade studies and make vs. buy

• Give the Vehicle Assembly ME team tooling cost, lead-time, capital and rate data for automation trades (manual vs. semi-automated vs. fully automated). Provide the same for make-vs-buy decisions on tooling and automation equipment.
• Build should-cost and rate models that show how design and automation choices affect cost, capital investment, schedule and quality.
• Write the requirements in RFQ packages for tooling and automation, and help evaluate supplier quotes.

Lead R&D

• Set and run a tooling and automation R&D roadmap aimed at faster, cheaper, more reliable production.
• Lead R&D on reconfigurable and low-cost fixturing, additive tooling, fixtureless and vision-guided assembly, and robotic drilling and fastening.
• Plan and run designed experiments (DOE). Build test articles and prototype cells, analyze results with sound statistics, and publish findings.
• Capture the inventions you develop and work with Legal to patent them.
• Design and deliver prototype tooling for development and validation builds, and lead manufacturing trials to prove new processes on real hardware.
• Release proven processes to production. Write process specs, and define qualification and acceptance criteria. Show process capability (Cp/Cpk) and measurement capability (GR&R), and set inspection methods with Quality.

Own the tool life cycle and support suppliers

• Own the life cycle of critical tools: feasibility and simulation, design, build, buyoff at the supplier, delivery and handoff to production.
• Design and oversee the build of critical fixtures, jigs, end effectors and assembly tooling.
• Run tool design reviews and buyoffs at tool shops.
• Bring tooling expertise to design and process FMEAs (DFMEAs and PFMEAs). Maintain a library of known failure modes and proven controls.
• Lead root cause analysis on tooling-related escapes and repeat defects. Mentor engineers and help build Mach's DFMA function.

Required Qualifications

• BS in Mechanical, Manufacturing or Industrial Engineering, or equivalent experience.
• 8+ years designing production tooling, fixtures or end effectors for automated or high-rate assembly in aerospace, automotive, defense or consumer electronics.
• Expert in GD&T (ASME Y14.5), datum schemes, and tolerance stack-ups across parts and tooling, including dimensional variation analysis.
• Experience integrating tooling with robots and automated cells, including selecting equipment and justifying ROI.
• A track record of writing design standards, design guides or process specs.
• Strong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics and ROI.
• Skilled in 3D CAD (NX, CATIA, SolidWorks or similar).
• A first-principles thinker with a bias for action, who challenges assumptions with data.
• Comfortable on the production floor and in the lab, not just at a desk.
• A clear writer who can influence design decisions.

Preferred Qualifications

• Journeyman Tool and Die Maker certification or an equivalent toolmaker background.
• MS in Mechanical or Manufacturing Engineering or a related field.
• Experience with both aerospace assembly tooling and automotive assembly automation.
• Familiarity with PLCs, robot programming and machine safety standards.
• Large-scale metrology.
• Formal DFMA methods (for example, Boothroyd Dewhurst), should-cost modeling, and value engineering programs with measured savings.
• Experience with assembly and robot simulation tools (for example, Siemens Process Simulate or DELMIA).
• Experience leading DFMEAs and PFMEAs.
• Patents, publications, or processes you developed and put into production.
• Experience in an AS9100 or defense production environment.
• Lean or Six Sigma certification.

Additional Requirements

• Available to work extended hours and weekends as needed