Senior Staff DFM Manufacturing Engineer

Boston Dynamics is adding a Senior Staff DFM Manufacturing Engineer to our prototype operations team. As a Senior Staff DFM Manufacturing Engineer, you will serve as the critical technical bridge between Hardware Engineering and our internal Precision Shop. This role is essential for transforming complex, next-generation robotic designs into high-precision machined components. You will own the manufacturing feedback loop, ensuring that design intent is perfectly balanced with machining capabilities to support rapid prototype iterations and low-volume production.

You will leverage expert-level knowledge of machining processes, tooling, and Design for Manufacturing (DFM) to optimize part geometry for manufacturability, cost, and lead time. If you thrive in a fast-paced R&D environment where you can directly influence the physical realization of world-class robots, this is the role for you.

Boston Dynamics is a world leader in mobile robots, tackling some of the toughest robotics challenges. For years, our awe-inspiring viral videos on YouTube have shown the world what remarkably capable robots can do. Now we are quickly becoming a recognized leader in automation solutions for industrial applications and warehouse logistics.  

How you will make an impact:

• DFM/DFA Collaboration: Lead DFX efforts with design engineering teams throughout product development to provide expert DFM and DFA input for machined components, ensuring they can be efficiently produced and serviced.

• Technical Bridge: Serve as the primary point of contact for design engineers to interpret technical drawings and reconcile manufacturing constraints with performance requirements.

• Precision Quality Control: Apply expert knowledge of GD&T to define inspection protocols and verify that machined components meet rigorous dimensional and performance standards.

• Root Cause Analysis: Lead troubleshooting efforts for system and process related issues, identifying root causes and implementing corrective actions to improve yield and part quality.

• Continuous Improvement: Champion Lean Manufacturing initiatives within the precision shop to reduce cycle times and enhance material flow.

• Documentation: Create and maintain detailed process documentation, setup sheets, and work instructions for machinists.

• Mentoring: Mentoring and coaching junior engineers and technicians on DFX, good manufacturing practices, technical documentation.

You Bring:

• Education: Bachelor’s or Master’s degree in Mechanical, Manufacturing, Industrial Engineering, or a related field, or equivalent experience.

• Professional Experience: At least 10 years of relevant experience in manufacturing engineering, process development, or advanced manufacturing, specifically within a machining-intensive environment.

• Machining Expertise: Expert-level understanding of precision machining capabilities (e.g., multi-axis milling, turning, grinding) and the physical constraints of various materials.

• CAD Proficiency: Strong proficiency in CAD software (SolidWorks, CATIA, or similar) for fixture design and review of engineering drawings.

• GD&T Mastery: Deep understanding of Geometric Dimensioning & Tolerancing (ASME Y14.5) and its application in both design for manufacturing and inspection.

• Communication Skills: Proven ability to provide constructive technical feedback and influence design stakeholders across engineering, manufacturing, and leadership teams.

• Problem Solving: Exceptional troubleshooting skills with a hands-on approach to resolving mechanical and process-related challenges.

• Environment: Comfortable working in a fast-paced, iterative R&D setting where designs and processes evolve rapidly.

• Process Control: Experience building process controls and quality systems (e.g., 8D, RCCA) to ensure build quality and alignment with performance requirements.

Nice to Have:

• Experience supporting robotics or aerospace development programs specifically within an NPI (New Product Introduction) context.

• Advanced knowledge of CAM software (e.g., Hypermill, Cimatron, Esprit) and CNC programming.

• Experience with additive manufacturing or rapid prototyping as a complement to traditiona