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 volumestandard features and the tolerances each process can holdworked 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 controlgate, vent and flow-path design, checked with draping and mold-filling simulationwall thickness and transitions, radii, draft, molded-in features and insertsnet-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 rateprocess selection, such as HP-RTM vs. compression molding vs. AFP or ATLbuilding 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…