Senior Manufacturing Engineer, RadarRedondo Beach, CA - Relocation Assistance ProvidedThe JobOur client is seeking a senior manufacturing engineer with deep expertise in the high-reliability assembly and integration of avionics and electromechanical systems for hypersonic missile vehicles. This role focuses on developing, optimizing, and scaling manufacturing processes for complex avionics hardware-including printed circuit board assemblies (PCBA), wire harnesses, electronic enclosures, sensors, actuators, connectors, and electromechanical subassemblies-to achieve repeatable, high-yield production.
You will serve as the technical authority on avionics electromechanical manufacturing, partnering with design, integration & test, quality, supply chain, and automation teams to transition advanced avionics from prototype to high-rate production while meeting stringent DoD, AS9100, IPC, and mission-critical reliability standards.
Functions- Lead manufacturing process development for avionics electromechanical assembly, including PCBA integration, conformal coating, potting, wire harness routing, connector termination, and enclosure sealing.
- Design and qualify production tooling, fixtures, automated work cells, and test equipment for precision electromechanical build and functional verification.
- Execute Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, and control plans to drive first-pass yield >95% and aggressive cycle-time reduction.
- Establish statistical process control (SPC), in-process inspection, and metrology strategies for critical avionics parameters (torque, continuity, insulation resistance, leak testing).
- Scale production from low-rate initial production (LRIP) to full-rate manufacturing, including line balancing, capacity modeling, and cost-reduction initiatives.
- Perform root-cause analysis and corrective actions for assembly defects using 8D, fishbone, and fault-tree methods; support MRB/FRB dispositions.
- Author and maintain detailed work instructions, travelers, and quality records compliant with customer requirements.
- Collaborate with suppliers on incoming material qualification for PCBs, connectors, and electromechanical components.
- Drive continuous improvement projects targeting cost, quality, and throughput for next-generation hypersonic avionics programs.
Qualifications- Bachelor's in Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, or related field.
- 7+ years in manufacturing engineering for complex aerospace or defense electronics hardware.
- 4+ years specifically supporting avionics or electromechanical assembly and integration (high-reliability electronics preferred).
- Proven success transitioning avionics hardware from prototype through LRIP to full-rate production.
Preferred Skills- Proficient with 3D CAD (SolidWorks or NX), GD&T (ASME Y14.5), and tolerance stack-up analysis.
- Strong experience in precision electromechanical assembly processes, including soldering, crimping, potting, adhesive bonding, and cleanroom/ESD protocols.
- Familiarity with ERP/MES systems and manufacturing execution for full aerospace traceability.
- Working knowledge of environmental stress screening (ESS), vibration, thermal cycling, and functional test integration for avionics.
- Direct work on missile, hypersonic, or high-reliability avionics systems for DoD programs.
- Experience in fast-paced defense or space environments (e.g., Anduril or SpaceX)
- Background with harsh-environment electronics (high-G, thermal extremes, radiation).
- Track record of implementing automation for electromechanical assembly and achieving significant cost or cycle-time reductions.
- Familiarity with ITAR-controlled programs and classified manufacturing protocols.
