Process Development Engineer - Dewar Manufacturing

Safran Defense & Space Inc. (Safran DSI), headquartered in Arlington, Va., is a leading U.S. aerospace company dedicated to supporting national defense and space missions. As a trusted partner to the U.S. armed forces, government agencies, and commercial sectors, Safran DSI delivers advanced technology solutions through its specialized business units: Assured PNT, Attollo Engineering, Geospatial AI, Optronics, Space Solutions, and Testing & Telemetry. Safran DSI Business Unit: Attollo Engineering

ABOUT OUR MISSION:

Join the forefront of innovation and make an impact at Safran Defense & Space, Inc.! Safran Defense & Space Inc. (Safran DSI), headquartered in Arlington, Va., is a leading U.S. aerospace company dedicated to supporting national defense and space missions. As a trusted partner to the U.S. armed forces, government agencies, and commercial sectors, Safran DSI delivers advanced technology solutions through its specialized business units: Assured PNT, Attollo Engineering, Geospatial AI, Optronics, Space Solutions, and Testing & Telemetry. Attollo Engineering is a designer and manufacturer of cutting-edge infrared cameras and laser sensor systems for defense and industrial applications. Leveraging extensive expertise in the electro-optical market, systems design, and packaging, Attollo delivers superior solutions for system integrators, original equipment manufacturers, and custom applications. Their commitment to quality engineering empowers Safran DSI to provide innovative and reliable technology to its partners. If you’re ready to join our mission and serve those who serve, Safran DSI is the perfect place for you to take your career to the next level. Make a real difference and be part of something extraordinary. Apply now and help us build the future of defense and space.

POSITION PROFILE:

The Process Development Engineer of Dewar Manufacturing develops, validates, documents, and transitions new manufacturing processes into production for integrated dewar cooler assemblies (IDCAs). The position operates at the interface of product engineering and manufacturing, applying engineering principles and independent judgment to determine process approach, establish process parameters and controls, and resolve manufacturability issues prior to and during production release. The incumbent partners with design engineers, manufacturing technicians, production personnel, quality, and suppliers to ensure dewar products are manufactured safely, repeatably, and efficiently against quality, cost, and schedule objectives. The position exercises discretion in evaluating alternative process methods and recommending changes affecting production yield, cost, and cycle time.

RESPONSIBILITIES:

• Develop and optimize manufacturing processes for new dewar products from prototype through full-rate production.
• Design and validate production tooling, fixtures, and assembly aids to improve quality, efficiency, and repeatability.
• Lead manufacturing readiness and New Product Introduction (NPI) activities, including prototype builds, process validation, and production transition.
• Establish and qualify manufacturing processes through process development, testing, and continuous improvement methodologies.
• Create and maintain manufacturing documentation, including work instructions, process flows, assembly procedures, and tooling documentation.
• Provide hands-on support to production by troubleshooting manufacturing issues, performing root cause analysis, and implementing corrective actions.
• Partner with engineering, quality, supply chain, manufacturing, and external vendors to improve manufacturability, support product development, and drive Design for Manufacturing (DFM) initiatives.
• Continuously improve manufacturing processes to increase yield, reduce cycle time, and enhance product quality and operational efficiency.
• Provides technical direction to Manufacturing Engineering Technicians and production personnel on process development activities; does not hold hiring, discipline, or performance management authority.
• Perform other duties as assigned

WHAT YOU’LL NEED TO BE SUCCESSFUL:

• Bachelor’s degree in engineering or physics
• 3+ years of experience developing manufacturing processes
• Experience taking products from prototype through production
• Strong understanding of Design for Manufacturing (DFM) and Design for Assembly (DFA)
• Experience developing production tooling and fixtures
• Experience writing manufacturing documentation and work instructions
• Experience with GD&T and tolerance stack-up analysis
• Proficiency in SolidWorks
• Strong understanding of precision assembly techniques
• Experience working in cleanroom or controlled manufacturing environments preferred
• Strong analytical and troubleshooting skills
• Excellent communication and project management skills
• Requires U.S. Citizenship or Permanent Resident Status required.

IDEALLY, YOU’LL ALSO HAVE:

• Experience with one or more of the following: Cryogenic systems, Vacuum systems, Integrated Dewar Cooler Assemblies (IDCAs), Hermetic packaging, Glass-to-metal seals, Laser welding, Resistance welding, Wire bonding, Die attach, Helium leak testing, Residual Gas Analysis (RGA), Optical alignment, Design of Experiments (DOE), Statistical Process Control (SPC), Failure Mode and Effects Analysis (FMEA), Lean Manufacturing, Six Sigma, Process validation, Automation of precision assembly processes
• SolidWorks PDM, Minitab, MATLAB or Python, ERP/MRP Systems (SAP a plus), CAD/CAM Software, Statistical Analysis software.
• Familiarity with tooling design, modification, or procurement processes
• Experience working with engineering and cross-functional teams
• Experience in cleanrooms or controlled manufacturing environments
• Experience working in an ITAR-regulated environment

SALARY RANGE: $120,000-$155,000 annual salary, plus participation in individual performance bonus plan. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of the role. EOE/AA/M/F/Vets – US Protected Individual status required (US citizen, lawful permanent resident, asylee, refugee or temporary resident (as defined at 8 USC 1160(a).