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 traditional machining.

• Familiarity with PLM systems (e.g., Arena, Enovia) for engineering change control and documentation management.

• Experience with cobots and automation systems (e.g., Universal Robotics, FANUC).

We are interested in every qualified candidate who is eligible to work in the United States. However, we are not able to sponsor visas for this position.

The salary range for this position will be clearly stated in the job posting as required by Massachusetts law. The base pay range for this position is between $135,000 - $167,000. Base pay will depend on multiple individualized factors including, but not limited to internal equity, job related knowledge, skills and experience. This range represents a good faith estimate of compensation at the time of posting.

Boston Dynamics will never ask you to divulge your personal financial or account information as part of its recruiting process.

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