Prototype Manufacturing Engineer, Mechanical & Fluid Systems

Costa Mesa · Costa Mesa, CA (OC-00) · USD 129,000-171,000 · 5+ years experience · Onsite · Posted Oct 9, 2026

At a glance

The Prototype Manufacturing Engineer will execute first builds and prototype manufacturing for mechanical, structural, thermal management, and fluid systems within the Air Dominance & Strike portfolio.
This role acts as a bridge between design intent and physical reality, working from incomplete design definitions to establish MVP work instructions and buildability feedback.
The position requires a hands-on engineer to manage cross-program builds, resolve manufacturing issues in real-time, and document lessons learned to support future production.

Execute first builds of new mechanical, structural, thermal, and fluid system hardware using preliminary or incomplete design inputs.
Develop MVP work instructions, including assembly sequences, tooling needs, and process notes for repeatability.
Establish preliminary BOM structures and make/buy determinations based on first-build experience.
Provide structured design feedback to engineers regarding buildability, checkability, and repeatability.
Document lessons learned to feed into formal DFM/DFA reviews and design trade studies.
Build and support Hardware-in-the-Loop (HIL) units such as Ironbirds and Copperbirds.
Identify and resolve manufacturing issues on the shop floor, including fit, interference, and routing conflicts.
Develop or source prototype tooling, fixtures, and assembly aids.
Collaborate with SME manufacturing engineers to validate process assumptions for welding, composite layup, and adhesive bonding.
Support the transition of hardware to early production by transferring documentation and BOM structures to the product-owning team.

Bachelor's degree in Mechanical, Aerospace, Manufacturing, or Industrial Engineering.
5+ years of experience in manufacturing engineering, prototype/development manufacturing, or NPI.
Demonstrated experience executing first builds of mechanical or electromechanical hardware with incomplete design inputs.
Practical knowledge of CNC machining, sheet metal fabrication, welding, mechanical fastening, composite fabrication, tube bending, and adhesive bonding.
Ability to read mechanical drawings, interpret GD&T, and work from 3D models.
Experience writing work instructions, assembly procedures, or process documentation.
Strong communication skills with the ability to provide direct, specific design feedback.
Comfort working across multiple programs simultaneously.
Self-directed and resourceful approach to working with imperfect information.
Must be a U.S. Person due to export control requirements.

Role requires 15-20% travel to production sites, supplier facilities, and integration locations.
Position is based in Costa Mesa, CA.

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