Lead Manufacturing Engineer, DFMA - Joining

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.

• •Write, publish and maintain Mach's Joining DFMA guide. It should cover:
• •design rules, with the reasoning and test data behind them
• •preferred fasteners, adhesives and joining processes
• •standard joint features and tolerances
• •worked examples and review checklists
• •Own Mach's preferred fastener and adhesive lists. Cut unique part numbers and drive commonality across programs.
• •Define joint design rules:
• •fasteners: preload and torque, edge distance and pitch, thread engagement, inserts and locking methods
• •galvanic compatibility
• •bondlines: overlap, thickness control and surface prep
• •Set standards for automated fastening and dispensing: torque-angle monitoring, auto-feed fasteners, bead geometry and in-process inspection.
• •Define the DFMA sign-off criteria for design gates and hold programs to them.
• •Set and track DFMA metrics for each program, such as part count, unique fastener count, assembly time, first-pass yield and cost.
• •Keep the guide current with test results, production lessons and supplier input. Train design and manufacturing engineers to apply it.

Own torque tooling in the prototype factory

• •Own torque tooling procurement: write tool specs, choose vendors, run quotes, manage lead times and own the tooling budget.
• •Deploy tools on the floor:
• •set up tool programs and torque strategies (torque, torque-angle, yield control)
• •connect tool controllers to the production tracking system (MES) so every result is recorded
• •Build torque mistake-proofing into each station, such as socket selectors, fastener count checks, and interlocks that run the right tool program for each joint.
• •Run the torque tool calibration and maintenance program. Verify tool capability on real joints and set residual (audit) torque checks with Quality.

• •Review vehicle architecture and material choices at concept, before designs lock, with an eye to how parts will be joined.
• •Run DFMA studies at the part, assembly and system level, and give design teams specific feedback backed by data.
• •Drive content reduction, simpler assembly and build-in-quality. Push for wider tolerances where performance allows, and for joints that suit automation.
• •Lead value engineering on released designs: challenge assumptions and take out cost.

Enable trade studies and make vs. buy

• •Set the rules for choosing adhesive, mechanical or hybrid joints. Develop the data, cost models and decision criteria for adhesive-vs-fastener and other trade studies.
• •Build should-cost, cycle-time and rate models that show how joining choices affect cost, capital investment, schedule and quality.

Lead R&D

Set and run a joining R&D roadmap aimed at faster, cheaper, more reliable production.

Plan and run designed experiments (DOE). Build coupons and test articles, test to failure, analyze results with sound statistics, and publish findings.

Release proven processes to production. Write process specs, and define qualification and acceptance criteria.