Senior Automation & Controls Engineer - Defense Energetics Manufacturing

Senior Automation & Controls Engineer - Defense Energetics Manufacturing

Waltham, Massachusetts | On-site

Join an early-stage advanced manufacturing company developing highly automated production systems for critical defense applications. The team is combining complex chemistry, industrial automation, and purpose-built manufacturing equipment to create safer and more scalable ways to produce energetic materials. As a Senior Automation & Controls Engineer, you will own controls development from architecture and programming through commissioning and production support. This is a hands-on engineering role for someone who can work directly with PLCs, instrumentation, robotics, motion systems, and industrial hardware rather than operating primarily at the design or management level.

Automation is central to the product itself. The goal is to build highly autonomous production systems that minimize human exposure to hazardous processes while maintaining tight control over chemistry and manufacturing performance. Candidates should be comfortable supporting defense applications and working around energetic materials.

• Design, program, deploy, and maintain industrial control systems for automated chemical production equipment
• Develop Siemens PLC programs using TIA Portal for reactors, fluid systems, thermal systems, material handling, and supporting equipment
• Build control logic for startup, normal operation, process transitions, upset conditions, and safe shutdown sequences
• Develop SCADA and HMI systems that support both autonomous operation and clear operator visibility
• Configure Ignition-based SCADA environments, operator interfaces, alarms, data logging, and system diagnostics
• Integrate pressure, temperature, flow, level, concentration, and other process instrumentation into automated control systems
• Integrate robotics, servos, VFDs, valves, actuators, vision systems, and industrial communication networks
• Implement machine and process safety systems using safety PLCs, fail-safe I/O, safety-rated motion, and related technologies
• Translate chemistry and process requirements into control strategies, interlocks, operating limits, and safety logic
• Support electrical control-panel architecture, wiring design, field termination, and integration of 480 VAC and 24 VDC systems
• Lead hands-on commissioning, debugging, hardware-in-the-loop testing, and factory or site acceptance testing
• Troubleshoot controls software, electrical hardware, instrumentation, valves, actuators, and communication issues during development and production
• Support root cause analysis and corrective actions for equipment and process failures
• Work directly with mechanical, chemistry, process, and manufacturing engineers throughout system development
• Support commissioning and testing at a nearby pilot manufacturing facility as systems move from development into larger-scale operation

• Bachelor's degree in Electrical Engineering, Mechanical Engineering, Robotics, Mechatronics, Chemical Engineering, or a related technical discipline
• 4+ years of experience in industrial controls, automation, robotics, or manufacturing systems
• Strong hands-on PLC programming experience
• Proficiency with Siemens TIA Portal
• Experience with SCADA systems such as Ignition
• Demonstrated experience taking an automation or controls system from initial architecture through commissioning on physical equipment
• Experience integrating sensors, instrumentation, motors, drives, valves, actuators, and industrial equipment
• Ability to troubleshoot both controls software and hardware directly on manufacturing equipment
• Familiarity with industrial electrical systems and control-panel architecture
• Experience with safety-rated controls, machine safeguarding, or fail-safe systems
• Strong debugging and problem-solving skills
• Comfortable working directly in laboratory, fabrication, commissioning, and plant environments
• U.S. Person as defined by applicable U.S. export-control regulations
• Ability to obtain a U.S. security clearance
• Ability to work on-site and travel periodically between development and pilot facilities
• Ability to lift up to 50 pounds

• Expe…