Manufacturing Engineer
$90,000–$125,000 year
On-site · Stafford, Virginia, United States
Job Summary
Lead hands-on integration of electrical, electronic, and mechanical subsystems for UAVs, including avionics, wiring harnesses, sensors, actuators, power systems, propulsion, and airframe components. Troubleshoot and resolve build issues on the production floor, perform functional testing and calibration, and ensure repeatable, compliant assembly processes. Own NPI from prototypes to full-rate production by developing manufacturing processes, tooling, fixtures, and test methods. Interpret engineering drawings, PCBA schematics, wiring diagrams, BOMs, and configuration requirements; create and maintain Assembly Work Instructions, SOPs, quality checks, and production routers. Drive process optimization through lean, 5 Whys, DMAIC, and FRACAS; contribute to design-for-manufacturability decisions and supplier collaboration. Ensure compliance with AS9100, ITAR, and defense documentation; coordinate with R&D, design engineering, and supply chain to deliver reliable, manufacturable products for high-reliability electromechanical UAV systems.
Required Qualifications
- Bachelor’s degree in Mechanical, Electrical, Manufacturing Engineering, or related field
- 5+ years of experience in manufacturing or production engineering within aerospace/defense/unmanned systems/high-reliability products
- Proficiency in modifying and updating engineering drawings, CAD
- U.S. citizenship or Active Greencard with ability to obtain Clearance after hire
- Experience writing and maintaining SOPs
- Strong background in production operations and continuous improvement methodologies
- Experience with manufacturing processes such as CNC, Injection Molding, Sheet Metal, 3D printing, Composites
- Experience with mechanical assembly, GD&T, torque specs, vibration/shock testing
- Background in lean, six sigma, line balancing, continuous improvement
- Experience with AS9100, ITAR, and defense production documentation requirements
- Hands-on wiring harness assembly, PCB integration, and basic electronics troubleshooting
- Experience with assembly, testing, and troubleshooting of electro-mechanical systems
- Knowledge of NPI processes and design-for-manufacturing (DFM)
- Ability to interpret GD&T, PCBA schematics, BOMs, and specs
- Onsite daily work in a hands-on production environment
- Preferred: UAV/defense systems experience, flight control systems, IMUs, telemetry, embedded electronics
- Experience supporting FAI, MRB, FRACAS, configuration management, and DoD reporting
- Python or scripting knowledge for testing automation
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