Senior Design Engineer, DFM / DFA

WHAT YOU’LL DO

As a Mechanical Design Engineer focused on DFM/DFA, you will sit at the critical intersection of product design and production reality. You will be directly responsible for designing robust, mission-ready, and highly manufacturable hardware across Anduril’s portfolio of autonomous air, land, and maritime systems. You will own components and assemblies from concept through prototype fabrication and high-rate production, ensuring our hardware can be rapidly built, scaled, and deployed at the speed of mission need.

Key Responsibilities:

• Design for Scale: Apply rigorous DFM and DFA principles across all phases of product development to maximize production throughput, reliability, and cost-efficiency.
• Multi-Discipline Mechanical Design: Design parts and complex assemblies leveraging a wide range of manufacturing processes:
  • Welded structures (MIG, TIG, FCAW, and automated processes)
  • Precision 3-axis and 5-axis CNC machining
  • Injection-molded plastics and tooling considerations
  • Advanced composite manufacturing (layup, molding, and secondary operations)
  • Structural bonding, encapsulation, and adhesive joining
• Drawing Definition & GD&T: Author, check, and release fully defined engineering drawing packages in strict accordance with ASME Y14.5 standards.
• Production Enablement: Develop detailed, visual work instructions, process sheets, and assembly documentation that enable seamless execution on the production floor.
• Engineering Analysis: Perform comprehensive 1D/3D tolerance stack-up analyses, design reviews, and DFMEAs to de-risk manufacturing and assembly bottlenecks early.
• Floor Collaboration: Work shoulder-to-shoulder with Manufacturing, Tooling, Quality, and Supply Chain teams to troubleshoot issues, implement rapid design iterations, and streamline production.
• Mentorship & Technical Leadership: Mentor junior hardware engineers in drawing standards, GD&T application, and practical manufacturing best practices.

REQUIRED QUALIFICATIONS

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, or a related field.
• 7+ years of hands-on mechanical design experience with a deep, proven focus on Design for Manufacturing (DFM) and Design for Assembly (DFA).
• High proficiency with modern 3D CAD software (SolidWorks, NX, Creo) and associated PDM/PLM systems.
• Expert-level understanding and practical application of ASME Y14.5 (GD&T) for engineering drawings and tolerance stack-ups.
• Deep domain experience designing for at least three of the following:
  • Complex weldments and welded joint architecture
  • Precision machining and sheet metal
  • Tooling and part design for injection molding
  • Composite structures and manufacturing techniques
  • Structural bonding and adhesive joining
• Experience creating clear, step-by-step manufacturing documentation, process specifications, and assembly instructions.
• Must be eligible to obtain / maintain US Security Clearance.