Senior Staff DFM Manufacturing Engineer

Senior Staff DFM Manufacturing Engineer

Boston Dynamics is adding a Senior Staff DFM Manufacturing Engineer to our prototype operations team. As a Senior Staff DFM Manufacturing Engineer, you will serve as the critical technical bridge between Hardware Engineering and our internal Precision Shop. This role is essential for transforming complex, next-generation robotic designs into high-precision machined components. You will own the manufacturing feedback loop, ensuring that design intent is perfectly balanced with machining capabilities to support rapid prototype iterations and low-volume production.

You will leverage expert-level knowledge of machining processes, tooling, and Design for Manufacturing (DFM) to optimize part geometry for manufacturability, cost, and lead time. If you thrive in a fast-paced R&D environment where you can directly influence the physical realization of world-class robots, this is the role for you.

Boston Dynamics is a world leader in mobile robots, tackling some of the toughest robotics challenges. For years, our awe-inspiring viral videos on You Tube have shown the world what remarkably capable robots can do. Now we are quickly becoming a recognized leader in automation solutions for industrial applications and warehouse logistics.

How you will make an impact:

• DFM/DFA
  
  Collaboration:
  
  Lead DFX efforts with design engineering teams throughout product development to provide expert DFM and DFA input for machined components, ensuring they can be efficiently produced and serviced.
• Technical Bridge:
  Serve as the primary point of contact for design engineers to interpret technical drawings and reconcile manufacturing constraints with performance requirements.
• Precision Quality Control:
  Apply expert knowledge of GD&T to define inspection protocols and verify that machined components meet rigorous dimensional and performance standards.
• Root Cause Analysis:
  Lead troubleshooting efforts for system and process related issues, identifying root causes and implementing corrective actions to improve yield and part quality.
• Continuous Improvement:
  Champion Lean Manufacturing initiatives within the precision shop to reduce cycle times and enhance material flow.
• Documentation:
  Create and maintain detailed process documentation, setup sheets, and work instructions for machinists.
• Mentoring:
  Mentoring and coaching junior engineers and technicians on DFX, good manufacturing practices, technical documentation.

You Bring:

• Education:
  
  Bachelor's or Master's degree in Mechanical, Manufacturing, Industrial Engineering, or a related field, or equivalent experience.
• Professional
  
  Experience:
  
  At least 10 years of relevant experience in manufacturing engineering, process development, or advanced manufacturing, specifically within a machining-intensive environment.
• Machining Expertise:
  Expert-level understanding of precision machining capabilities (e.g., multi-axis milling, turning, grinding) and the physical constraints of various materials.
• CAD Proficiency:
  Strong proficiency in CAD software (Solid Works, CATIA, or similar) for fixture design and review of engineering drawings.
• GD&T Mastery:
  Deep understanding of Geometric Dimensioning & Tolerancing (ASME Y14.5) and its application in both design for manufacturing and inspection.
• Communication
  
  Skills:
  
  Proven ability to provide constructive technical feedback and influence design stakeholders across engineering, manufacturing, and leadership teams.
• Problem Solving:
  Exceptional troubleshooting skills with a hands-on approach to resolving mechanical and process-related challenges.
• Environment:
  Comfortable working in a fast-paced, iterative R&D setting where designs and processes evolve rapidly.
• Process Control:
  Experience building process controls and quality systems (e.g., 8D, RCCA) to ensure build quality and alignment with performance requirements.

Nice to Have:

• Experience supporting robotics or aerospace development programs specifically within an NPI (New Product Introduction) context.
• Advanced knowledge of CAM software (e.g., Hypermill, Cimatron, Esprit) and CNC programming.
• Experience with additive manufacturing or rapid prototyping as a complement to traditional…