Senior Manufacturing Engineer, DFMA - Composites

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 Senior Manufacturing Engineer, Composites, you'll be Mach's go-to expert on designing composite structures for high-rate production. You'll review designs at the part, assembly and system level from concept through production release. You'll also 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. Examples include snap-cure resins, net-shape automated preforming, and closed-loop process control that cut cycle time and scrap.

Key Responsibilities

Own the Composites DFMA guide

• Write, publish and maintain Mach's Composites DFMA guide for high-rate production:
  • design rules for each high-rate process, with reasoning and data behind them
  • preferred materials, processes and tooling approaches by part type and volume
  • standard features and the tolerances each process can hold
  • worked examples and review checklists
• Write design rules for LCM (RTM, HP-RTM, C-RTM, wet compression molding):
  • preform design: drapability, fiber shear limits, binder, and fiber volume control
  • gate, vent and flow-path design, checked with draping and mold-filling simulation
  • wall thickness and transitions, radii, draft, molded-in features and inserts
  • net-shape edges vs. trimmed edges
• Set rate-capable standards for preforming, injection, cure, demold, trim, drill and inspection in automated cells.
• Define the DFMA sign-off criteria for design gates, including a check that each part fits its target production line, and hold programs to them.
• Set and track DFMA metrics for each program, such as part count, cycle time, material utilization, first-pass yield, scrap rate and cost.

Shape designs early

• Advise vehicle architecture, material and process choices before designs lock.
• Match each part to the right high-rate process early, and design it to that line's capability.
• Drive part consolidation through molded-in features and co-molded assemblies.
• Define composites poka-yoke standards, for example asymmetric locators, in-line vision checks of fiber orientation and of tow and ply placement, insert-presence sensing and mold-close interlocks, indexing features for trim and drill, asymmetric hole patterns on mating parts
• Lead value engineering on released designs: challenge assumptions and take out cost.

Enable trade studies and make vs. buy

• Develop the data, cost models and decision criteria for:
  • metal vs. composite structures at rate
  • process selection, such as HP-RTM vs. compression molding vs. AFP or ATL
  • building in-house vs. outsourcing to a high-volume composites manufacturer
• Build should-cost, rate and material-utilization models that show how design choices affect cycle time, cost, schedule, quality and capital investment (presses, injection equipment, AFP and ATL machines, preforming cells and tooling).
• Use should-cost models to support Supply Chain in partner selection and negotiations.

Prepare designs for outsourcing and deploy partner lines

• Find and assess high-volume composites manufacturers, including automotive and industrial suppliers. Validate capability, capacity, quality.
• Build composites technical data packages: models and drawings, material and process specs, key characteristics, acceptance criteria and inspection plans.
• Bridge automotive launch practices (APQP, PPAP) with aerospace and defense quality requirements (AS9100, AS9102 first article inspection).

Lead R&D

• Set and run a composites R&D roadmap aimed at shorter cycle times, more automation and less scrap.
• Lead R&D on:
  • snap-cure and fast-cure resins
  • automated and net-shape preforming
  • dry-fiber placement for infusion
  • thermoplastic tape placement and stamping
  • cure monitoring with closed-loop process control
• Plan and run designed experiments (DOE). Build coupons and test articles, test to failure, analyze results with sound statistics, and publish findings.

Support production and suppliers

• Own tooling feasibility, design reviews and buyoff for matched-metal molds, preform tools, and AFP and ATL tools, whether built for Mach or for a partner.
• Assess tool suppliers on site, and push them to best practices and lower investment.
• Bring composites expertise to design and process FMEAs (DFMEAs and PFMEAs). Maintain a library of known failure modes and proven controls.
• Mentor engineers and help build Mach's DFMA function.

Required Qualifications

• BS in Mechanical, Materials or Chemical Engineering, or equivalent experience.
• 7+ years in composite manufacturing, process or design engineering for high-rate production. You'll need hands-on experience with at least one of: HP-RTM or other LCM processes, AFP / ATL, or automated preforming or ply pick-and-place.
• Launched a high-rate composite part or production line, in-house or at an outside manufacturer. The launch should have included tooling, equipment, run-at-rate and ramp.
• Experience with draping and mold-filling simulation (for example, PAM-RTM or similar) and composite design tools (CATIA Composites Design, Fibersim or similar).
• A track record of writing design standards, 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.
• Working knowledge of GD&T (ASME Y14.5), tolerance stack-ups and DVA.
• Skilled in 3D CAD (NX, CATIA, SolidWorks or similar).

Preferred Qualifications

• MS or PhD in Materials Science, Aerospace Engineering or a related field.
• High-volume automotive composites experience at an OEM or Tier 1 supplier, for example HP-RTM or compression-molded structural parts.
• Experience at a composites equipment maker or automation integrator (presses, injection systems, AFP and ATL machines, or preforming cells).
• Familiarity with automotive launch practices (APQP, PPAP) and aerospace quality systems (AS9100, AS9102).
• Formal DFMA methods (for example, Boothroyd Dewhurst), should-cost modeling, and value engineering programs with measured savings.
• Lean or Six Sigma certification.

Additional Requirements

• Available to work extended hours and weekends as needed

ITAR Requirements

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.

Senior Engineer

$140,000—$180,000 USD

At Mach, we believe that compensation is more than just a paycheck. It's a comprehensive package designed to reward the time, skills, and expertise you bring to our team. We are committed to offering competitive compensation that is equitable, transparent, and aligned with market trends.

Key Elements of Our Compensation Philosophy:

• Competitive Salaries: We continuously research market rates to ensure our salaries are competitive with those in our industry and geographic location.
• Performance-Based Incentives: Our bonus structure is tied to both individual and company performance, creating a win-win scenario that motivates our team members to excel.
• Equity Participation: We offer stock options or equity to employees, ensuring that you share in the success and growth of the company.
• Benefit Packages: Our benefits include healthcare, dental and vision plans, retirement savings, and paid time off, because we understand that your well-being extends beyond the office.
• Professional Development: We allocate funds for continuing education, training, and career growth.
• Transparency: We are committed to openness about our compensation tiers and how decisions are made, ensuring trust and mutual respect.

By joining Mach, you’re not just accepting a job—you’re becoming a key part of a team that values your contributions and invests in your growth. Together, we aim to create a rewarding environment that sets the stage for long-term success.

Data Privacy
To view Mach Industries candidate data privacy policy, please visit https://machindustries.com/privacy-policy.

Disclosures

This position may require access to information protected under U.S. export control laws and regulations, including the Export Administration Regulations (EAR) and the International Traffic in Arms Regulations (ITAR). Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these U.S. export control laws and regulations without sponsorship for an export license.

Mach participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.

The salary range for this role is an estimate based on a wide range of compensation factors, inclusive of base salary only. Actual salary offers may vary based on (but not limited to) work experience, education and training, critical skills, and business considerations. Highly competitive equity grants are included in most offers and are considered part of Mach’s total compensation package. Mach offers benefits such as health insurance, retirement plans, and opportunities for professional development.

Mach is an equal opportunity employer committed to creating a diverse and inclusive workplace. All qualified applicants will be treated with respect and receive equal consideration for employment without regard to race, color, creed, religion, sex, gender identity, sexual orientation, national origin, disability, uniform service, Veteran status, age, or any other protected characteristic per federal, state, or local law, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws. If you’d like to defend the American way of life, please reach out!