Staff DFx Engineer, Mechanical & Fluid Systems

Job description

Job responsibilities

• Own and drive DFx analysis across mechanical, structural, thermal, and fluid systems subsystems for AD&S programs, with a primary focus on manufacturability, assembly, and cost.
• 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.
• 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 negotiate design trades that balance performance,…
• Assist in the selection and qualification of contract manufacturers for machined components, fabrications, composite structures, thermal management hardware, and fluid system assemblies — assessing supplier…
• Conduct supplier manufacturing assessments including facility reviews, process audits, and capability evaluations to determine readiness for production qualification.
• Develop and maintain 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.
• 12+ years of experience in manufacturing engineering, producibility engineering, or DFx with a significant focus on mechanical systems, thermal management, or fluid systems — with deep specialty expertise in at least…
• Strong technical depth in mechanical manufacturing processes: CNC machining, sheet metal fabrication, welding (TIG, MIG, electron beam, friction stir), brazing, composite layup and cure, bonding, casting, forging, and…
• Demonstrated experience leading DFM/DFA reviews and translating findings into measurable design improvements that reduce cost and improve producibility.
• Experience evaluating and qualifying contract manufacturers — including facility assessments, process capability reviews, and production readiness evaluations.
• Strong understanding of cost drivers in mechanical and fluid system production, with experience building or contributing to should-cost models.
• 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 (AS9100, NAS, AN/MS fittings, SAE AS specifications for fluid components).