Senior Staff Process Engineer

Boston Dynamics is a global leader in robotics innovation, renowned for developing highly advanced, dynamic robots that excel in mobility, dexterity, and intelligence. Our cutting-edge robots, including the iconic Atlas, Spot, and Stretch, are pushing the boundaries of automation and redefining how machines interact with the world. At Boston Dynamics, we blend advanced mechanical design, state-of-the-art control systems, and AI-driven perception to create robots capable of performing in unstructured, real-world environments.

We are looking for an expert  Sr. Staff Process Engineer to support the Atlas program, helping to transform groundbreaking research prototypes into reliable, scalable systems for manufacturing and field deployment.

As a Sr. Process Engineer - Atlas, you will play a critical role in the development and implementation of low-volume production processes, assembly workflows, and custom tooling to support the assembly, test, and integration of our next-generation humanoid robot. You will work closely with Hardware Engineering, Prototype Operations, Systems Engineering, Behavior and Software teams to ensure that cutting-edge designs can be efficiently and reliably built in a prototype and low-volume production environment.

This role requires expert-level technical expertise in cradle-to-grave process implementation, large production system/value-stream design, and an innovative spirit to bridge the gap between product design and manufacturing execution. You will oversee automation equipment, fixture, tool, and jig design and implementation to ensure process repeatability and product quality for Atlas builds. This role will also interface with our parent company, Hyundai Motor Group (HMG), leveraging their deep manufacturing expertise in the automotive sector.

Responsibilities:

• Develop, optimize, and implement rate production processes and assembly workflows for Atlas, from prototype through low-volume production with a focus on scaling for future production needs.

• Design and implement production system tools including material flow diagrams, value stream maps, floor layouts, and automation integrations.

• Collaborate with Hardware Engineering to provide DFM/DFA (Design for Manufacturing & Assembly) input throughout product development, ensuring manufacturability and serviceability.

• Design, fabricate, and validate custom fixtures, tools, and jigs to support mechanical assembly, precision alignment, and testing of electric motors and actuators, ensuring ergonomic and repeatable processes.

• Define assembly sequences, work instructions, and process documentation, including standard operating procedures (SOPs), visual aids, and training materials for assembly technicians.

• Support prototype builds in a hands-on capacity, troubleshooting assembly issues, identifying root causes, and driving corrective actions to improve processes and product designs.

• Implement process controls to ensure build quality, dimensional accuracy, and alignment with product performance requirements.

• Develop and implement inspection and test processes, including first article inspections (FAI), in-process quality checks, and final acceptance criteria.

• Collaborate with Supply Chain to ensure external fabrication and supplier processes align with internal manufacturing requirements and quality standards.

• Lead continuous improvement initiatives, applying Lean Manufacturing and Six Sigma methodologies to improve process efficiency, reduce cycle times, and increase yield.

• Drive tooling and equipment validation, ensuring custom fixtures and tools are fully qualified for use in production, including performing capability studies where necessary.

Qualifications:

• Bachelor's degree in Manufacturing, Mechanical, Industrial, Electrical Engineering, or a related field; Master’s degree or PhD a plus.

• At least 8-15 years of relevant experience in Process engineering, process development, or advanced manufacturing, preferably in robotics, aerospace, or complex electromechanical systems.

• Expert-level proficiency in CAD software (SolidWorks, CATIA, or similar) for tool/fixture design and review of engineering drawings.

• Proven track record of DFM/DFA collaboration with design teams to drive manufacturable and serviceable product designs.

• Hands-on experience developing and validating custom tooling, jigs, and fixtures to suppor