Senior DFx Engineer, Mechanical & Fluid Systems

Job description

Job responsibilities

• Execute DFx analysis across mechanical, structural, thermal, and fluid systems subsystems for AD&S programs, with a primary focus on manufacturability, assembly, and cost.
• Participate in and help lead structured DFM/DFA/DFC reviews at key design milestones, applying rigorous scoring to identify producibility and cost risks and drive design changes before they reach production.
• Participate in and help lead/facilitate DFMEAs with cross-functional teams. Use FMEA outputs to drive design changes, inspection strategies, and control plans.
• Work directly with SME manufacturing engineers and design engineers to evaluate designs, translate manufacturing constraints into actionable feedback, and support design trades that balance performance, producibility,…
• Support the selection and qualification of contract manufacturers for machined components, fabrications, composite structures, thermal hardware, and fluid system assemblies — assessing supplier manufacturing…
• Participate in supplier manufacturing assessments including facility reviews, process audits, and capability evaluations.
• Contribute to should-cost models and cost-driver analyses for mechanical and fluid system assemblies, identifying design changes that reduce unit cost without compromising quality or performance.
• Develop and maintain DFx standards, guidelines, and scorecards specific to mechanical manufacturing processes including CNC machining, sheet metal fabrication, welding, brazing, composite layup and bonding, tube…

Job requirements

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, Industrial Engineering, or a related field.
• 8+ years of experience in manufacturing engineering, producibility engineering, or DFx with a significant focus on mechanical systems, thermal management, or fluid systems — with specialty expertise in at least one of…
• Strong working knowledge of mechanical manufacturing processes: CNC machining, sheet metal fabrication, welding, brazing, composite layup and cure, bonding, casting, forging, and complex mechanical assembly.
• Experience participating in or leading DFM/DFA reviews and translating findings into measurable design improvements that reduce cost and improve producibility.
• Experience supporting contract manufacturer evaluations — including facility assessments, process capability reviews, or production readiness evaluations.
• Understanding of cost drivers in mechanical and fluid system production, with exposure to should-cost modeling or cost analysis.
• Ability to read and critically evaluate mechanical drawings, GD&T, 3D models, and assembly documentation for producibility and cost impact.
• Working knowledge of relevant standards and specifications for aerospace mechanical and fluid systems.