Manufacturing Engineer

Manufacturing Engineer

At SiFly, we're building a new category of aircraft: vertical-takeoff, long-endurance drones that deliver helicopter-level performance at drone economics. After thousands of flight tests and years of engineering, our NDAA-compliant platform flies more than 2 hours in hover or 3 hours in forward flight on a single charge — matching the capability of traditional helicopters at a fraction of their cost and operational burden. We merge aerial robotics, perception, and onboard intelligence to cut complexity and minimize human intervention, and our unique approach to communications and networking unlocks remote operations from day one. It's an ambitious mission, and we're a small team that moves fast.

Position Summary

We are seeking a hands-on Manufacturing Engineer to develop, implement, and improve manufacturing processes for complex electromechanical products. The role is heavily focused on electromechanical assembly, process development, tooling/fixtures, work instructions, DFM/DFA, production-line development, and PCBA integration. The successful candidate must have direct experience supporting products through NPI, production ramp, sustained manufacturing, and customer shipment; prototype-only or R&D-only experience is not sufficient. Working knowledge of PCB fabrication and PCBA manufacturing/assembly is required.

Key Responsibilities

• Develop, validate, and continuously improve electromechanical assembly processes from NPI through production ramp and sustained manufacturing.

• Define assembly sequences, process flows, workstation layouts, critical process parameters, inspection points, and acceptance criteria.

• Create and maintain work instructions, process specifications, manufacturing documentation, and standard work.

• Develop and qualify tooling, fixtures, jigs, gauges, and production equipment.

• Establish and control assembly processes including fastening/torque, adhesives, soldering, wiring/cables, connectors, thermal interfaces, and mechanical alignment.

• Develop PCBA integration processes and support PCB/PCBA manufacturing issues including SMT, through-hole, soldering, rework, handling, connectors, and mechanical interfaces.

• Lead/support DFM/DFA, PFMEA, control plans, process qualification, root-cause analysis, corrective actions, and manufacturing readiness reviews.

• Improve cycle time, throughput, labor efficiency, FPY, quality, line balance, and production capacity; support production-floor and supplier/CM troubleshooting.

Qualifications

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Mechatronics, Electrical Engineering, or related discipline; equivalent relevant technical education and experience may be considered.

• 5+ years of manufacturing engineering experience supporting complex electromechanical products.

• Required: direct experience with products that have been built, tested, released, and shipped to customers in a production environment.

• Experience supporting NPI, production launch/ramp, and sustained manufacturing.

• Strong hands-on experience with electromechanical assembly processes and products combining mechanical components, PCBAs, wiring/cabling, connectors, sensors, motors/actuators, and embedded electronics.

• Working knowledge of PCB fabrication and PCBA manufacturing/assembly, including SMT, through-hole, soldering, rework, inspection, and handling.

• Experience with DFM/DFA, tooling/fixtures, process validation, PFMEA/control plans, root-cause analysis, and continuous improvement.

• Demonstrated ability to improve cycle time, throughput, FPY, quality, and manufacturing efficiency and resolve issues directly on the production floor.

• Ability and willingness to travel domestically and internationally as required to support production builds, manufacturing transfers, suppliers, and contract manufacturers.

Preferred Qualifications

• Experience with UAVs/drones, robotics, autonomous systems, consumer electronics, industrial automation, or similar electromechanical products.

• Experience with PCB/PCBA/EMS suppliers, IPC workmanship standards, MES/ERP, manufacturing BOMs/routings, and serial-number traceability.

• Experience with contract manufacturers, manufacturing transfers, Lean/5S/standard work, and processes such as machining, molding, sheet metal, extrusion, composites, or finishing.
  
  Details
  On site in Santa Clara, CA
  
  Compensation: $130-$160k