Staff DFx Manufacturing Engineer

Costa Mesa · Costa Mesa, CA (OC-00) · USD 166,000-220,000 · 12+ years experience · Onsite · Posted Sep 23, 2026

At a glance

The Staff DFx Manufacturing Engineer will serve as the technical authority for design-for-manufacturability, assembly, and testability across avionics, electronics, and harnessing subsystems.
This role involves embedding with design teams to ensure hardware is producible at scale for autonomous aircraft, cruise missiles, and loitering munitions.
The position requires mentoring junior engineers and developing the DFx methodology and toolset to support organizational growth.

Own and drive the DFx process for avionics, electronics, and harnessing subsystems from concept through rate production.
Lead structured DFM/DFA/DFT reviews at key design milestones using a rigorous scoring methodology.
Provide real-time manufacturing feedback on PCBA layout, component selection, connector architecture, and test access.
Develop and maintain DFx standards, guidelines, and scorecards for electronics manufacturing processes.
Analyze designs across five key lenses to produce quantified risk assessments for engineering and program decisions.
Define test point access, boundary scan requirements, and functional test strategies for production-rate acceptance.
Partner with quality engineering to integrate DFx findings into inspection plans and process control strategies.
Collaborate with supply chain teams to assess supplier capability and support make-vs-buy decisions.
Build and evolve the DFx toolkit, including templates, rubrics, and lessons-learned databases.
Mentor and develop junior and mid-level manufacturing engineers on DFx principles.

Bachelor’s degree in Electrical, Manufacturing, Mechanical, or Industrial Engineering, or a related field.
12+ years of experience in manufacturing, process, or producibility engineering with a focus on electronics, avionics, or electromechanical assemblies.
Deep working knowledge of electronics manufacturing processes including SMT, soldering, conformal coating, potting, and box-build.
Demonstrated experience leading DFM/DFA/DFT reviews and translating findings into design improvements.
Proven ability to work cross-functionally and influence without positional authority.
Ability to read and evaluate electrical schematics, PCB layouts, harness drawings, and mechanical packaging.
Strong command of IPC standards (IPC-A-610, J-STD-001, IPC-620, IPC-6012).
Excellent written and verbal communication skills for presenting to engineering leadership.
Personal experience physically building or reworking electronic assemblies.
Must be a U.S. Person due to export control requirements.

Master’s degree in engineering or a related field.
Experience in aerospace or defense electronics production.
Familiarity with AS9100/AS9102 quality management systems and First Article Inspection.
Experience with PCBA insourcing or standing up electronics manufacturing lines.
Proficiency in ECAD tools such as Altium or KiCad.
Background in Design of Experiments (DOE), statistical process control, or Six Sigma.
Experience developing automated or semi-automated test solutions.
Appropriate clearance classification.

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