Manufacturing Engineer – Electronics, PCBA & NPI

Our client is seeking a hands‑on Manufacturing Engineer with a strong electrical engineering background to support New Product Introduction (NPI), electrical test development, and production readiness for electronic and electro‑mechanical systems. This role bridges electrical design and manufacturing, ensuring that processes, documentation, and test systems are robust, scalable, and aligned with product requirements.

The ideal candidate has experience interpreting electrical documentation, developing test processes, supporting PCBA manufacturing, and collaborating with cross‑functional teams and suppliers to resolve technical challenges.

Onsite | No Visa Sponsorship | Relocation Assistance: Yes

Responsibilities:

• Drive improvements in yield, reliability, and test coverage.
• Participate in design reviews with a focus on DFM and DFT for electronic systems.
• Serve as the primary technical point of contact for electrical and PCBA‑related documentation.
• Design and implement functional test systems, test fixtures, and automated test equipment (ATE)
• Support debugging, root‑cause analysis, and corrective actions for electrical and system‑level failures.
• Support supplier qualification, onboarding, and technical training for PCBA and electrical component suppliers.
• Collaborate with Electrical Engineering, Procurement, Quality, and Supplier Engineering to align on technical requirements.
• Define, develop, and optimize electrical assembly, integration, and test processes for PCBAs and electro‑mechanical systems.
• Interpret and clarify electrical schematics, PCB layouts, wiring diagrams, BOMs, and specifications for internal teams and suppliers.
• Lead NPI support: transition products from prototype to production, develop/validate electrical and manufacturing processes, and support pilot builds and ramp‑up.

Qualifications (Must-Haves)

• Familiarity with ERP and PLM systems.
• Strong understanding of NPI, DFM, and DFT principles.
• Experience working with contract manufacturers and PCBA suppliers.
• Proficiency interpreting schematics, PCB layouts, wiring diagrams, and BOMs.
• Familiarity with lab equipment (oscilloscopes, multimeters, power supplies, signal generators)
• 5+ years of Manufacturing Engineering experience in electronics, PCBA, or electro‑mechanical systems.
• Experience developing electrical test processes, including fixtures, instrumentation, and data acquisition.
• Bachelor's degree in Electrical Engineering (preferred) or in Manufacturing/Mechanical Engineering with strong electrical experience.
• Proficiency with CAD and ECAD tools (Altium, OrCAD) and manufacturing data systems (PDM/PLM such as Autodesk Vault or SolidWorks PDM)

Nice-to-Haves:

• Familiarity with EMI/EMC considerations and compliance testing.
• Experience with ATE, LabVIEW, or similar test‑automation software.
• Lean Six Sigma certification or equivalent process‑improvement training.
• Hands‑on experience with soldering, rework, and electronics troubleshooting.
• Knowledge of IPC standards (IPC‑A‑610, IPC‑2221) and electronics‑manufacturing best practices.

Additional Requirements:

• Occasional travel to suppliers or partner sites.
• Ability to work on‑site at the Stafford, VA facility.
• Strong communication and cross‑functional collaboration skills.
• Ability to manage multiple priorities in a fast‑paced production environment.