Senior Controls Engineer

Senior Automation & Controls Engineer - Defense Energetics ManufacturingWaltham, Massachusetts | On-siteOpportunity SummaryJoin an early-stage advanced manufacturing company developing highly automated production systems for critical defense applications. The team is combining complex chemistry, industrial automation, and purpose-built manufacturing equipment to create safer and more scalable ways to produce energetic materials. As a Senior Automation & Controls Engineer, you will own controls development from architecture and programming through commissioning and production support. This is a hands-on engineering role for someone who can work directly with PLCs, instrumentation, robotics, motion systems, and industrial hardware rather than operating primarily at the design or management level. Automation is central to the product itself. The goal is to build highly autonomous production systems that minimize human exposure to hazardous processes while maintaining tight control over chemistry and manufacturing performance. Candidates should be comfortable supporting defense applications and working around energetic materials.Job DutiesDesign, program, deploy, and maintain industrial control systems for automated chemical production equipmentDevelop Siemens PLC programs using TIA Portal for reactors, fluid systems, thermal systems, material handling, and supporting equipmentBuild control logic for startup, normal operation, process transitions, upset conditions, and safe shutdown sequencesDevelop SCADA and HMI systems that support both autonomous operation and clear operator visibilityConfigure Ignition-based SCADA environments, operator interfaces, alarms, data logging, and system diagnosticsIntegrate pressure, temperature, flow, level, concentration, and other process instrumentation into automated control systemsIntegrate robotics, servos, VFDs, valves, actuators, vision systems, and industrial communication networksImplement machine and process safety systems using safety PLCs, fail-safe I/O, safety-rated motion, and related technologiesTranslate chemistry and process requirements into control strategies, interlocks, operating limits, and safety logicSupport electrical control-panel architecture, wiring design, field termination, and integration of 480 VAC and 24 VDC systemsLead hands-on commissioning, debugging, hardware-in-the-loop testing, and factory or site acceptance testingTroubleshoot controls software, electrical hardware, instrumentation, valves, actuators, and communication issues during development and productionSupport root cause analysis and corrective actions for equipment and process failuresWork directly with mechanical, chemistry, process, and manufacturing engineers throughout system developmentSupport commissioning and testing at a nearby pilot manufacturing facility as systems move from development into larger-scale operationQualificationsBachelor's degree in Electrical Engineering, Mechanical Engineering, Robotics, Mechatronics, Chemical Engineering, or a related technical discipline4+ years of experience in industrial controls, automation, robotics, or manufacturing systemsStrong hands-on PLC programming experienceProficiency with Siemens TIA PortalExperience with SCADA systems such as IgnitionDemonstrated experience taking an automation or controls system from initial architecture through commissioning on physical equipmentExperience integrating sensors, instrumentation, motors, drives, valves, actuators, and industrial equipmentAbility to troubleshoot both controls software and hardware directly on manufacturing equipmentFamiliarity with industrial electrical systems and control-panel architectureExperience with safety-rated controls, machine safeguarding, or fail-safe systemsStrong debugging and problem-solving skillsComfortable working directly in laboratory, fabrication, commissioning, and plant environmentsU.S. Person as defined by applicable U.S. export-control regulationsAbility to obtain a U.S. security clearanceAbility to work on-site and travel periodically between development and pilot facilitiesAbility to lift up to 50 poundsPreferred ExperienceExperience automating chemical manufacturing, process equipment, continuous processes, batch systems, or other process-intensive manufacturing environmentsBackground in robotics, mechatronics, automated assembly, battery manufacturing, aerospace production, or other highly automated manufacturing environmentsExperience with hazardous processes or environments where system safety and fault response are criticalFamiliarity with Siemens safety PLCs, ProfiSafe, safety-rated motion, or similar platformsKnowledge of functional safety standards such as ISO 13849, IEC 61508, or ISO 10218Experience integrating multi-vendor automation hardware and industrial communication systemsExperience designing or supporting automated work cells and production linesProgramming experience with Python, C/C++, MATLAB, or similar languagesExperience with version-control or controls-project management tools such as GitHub or Siemens Project ServerExperience in defense, aerospace, energetics, battery manufacturing, industrial robotics, or other regulated manufacturing environmentsExperience building automation systems in an early-stage company or similarly high-ownership engineering environmentWhy Join UsOwn automation systems from initial design through commissioning and real production useWork directly on technically challenging industrial hardware rather than remaining focused on simulation or documentationHelp build highly autonomous manufacturing systems where automation is fundamental to both safety and production capabilityWork across robotics, controls, chemistry, mechanical engineering, and process developmentSee systems progress from development equipment into pilot-scale productionJoin an early-stage engineering team where individual engineers have meaningful technical ownershipOpportunity for equity participation and significant growth as the company scalesCompensation Details$140,000 - $200,000#LI-AV