Manufacturing Engineer

Scientific Applications & Research Associates, Inc. (SARA) is a world-class Defense Research and Development enterprise, with a charter to create new and emerging technology innovations in support of Commercial & Government organizations. We have expertise in RF, EMP, Pulsed Power, Acoustics, and Threat Warning Systems, and we prioritize partnering with our customers to address real-world problems with cost-effective solutions... that work.

SARA's High-Powered Electromagnetics division is seeking a highly motivated Manufacturing Engineer to support the transition of innovative products from prototype through low-rate production out of our Colorado Springs, CO facility. This role bridges engineering, manufacturing, and quality to develop production-ready designs, optimize manufacturing processes, and ensure successful execution of customer programs. The ideal candidate enjoys solving practical manufacturing challenges, improving production efficiency, and working hands-on alongside technicians and engineers to build high-quality hardware.

Core Responsibilities:

• Design mechanical products and assemblies with manufacturability, quality, and production scalability in mind
• Apply Design for Manufacturing (DFM) and Design for Assembly (DFA) principles throughout the design process
• Develop prototype hardware and transition designs into production-ready products
• Design and implement production tooling, fixtures, assembly aids, and jigs
• Support manufacturing teams by troubleshooting production and assembly issues while implementing corrective action activities
• Work closely with Manufacturing, Quality, and Program Management to achieve project objectives
• Perform engineering analyses and proof-of-concept evaluations to validate design solutions
• Support prototype, qualification, environmental, and production testing activities
• Lead and train teams while performing tolerance analyses and GD&T principles to optimize product performance and manufacturing repeatability
• Contribute to engineering drawings, Bills of Materials (BOMs), work instructions, and Technical Data Packages (TDPs)
• Support Engineering Change Notices (ECNs) and Engineering Change Orders (ECOs) by implementing design changes and maintaining accurate product documentation
• Identify opportunities to improve manufacturing efficiency, product quality, and assembly processes.
• Collaborate with suppliers to resolve technical and manufacturability challenges
• Provide technical guidance to technicians during prototype and production builds
• Perform other duties, assignments, and responsibilities as reasonably assigned by management in support of departmental, programmatic, and organizational objectives

Requirements:

• Bachelor's degree in Mechanical Engineering or a related engineering discipline
• 0 - 4 years of experience in production engineering, manufacturing engineering, or mechanical product development
• Proficiency with SolidWorks or equivalent CAD software
• Experience creating engineering drawings and manufacturing documentation
• Working knowledge of GD&T and production-focused design principles
• Experience supporting prototype or production builds
• Strong mechanical aptitude and practical problem-solving skills
• Ability to interpret customer requirements and develop practical engineering solutions
• Excellent written, verbal, and interpersonal communication skills
• Proficiency with Microsoft Office applications
• Ability to work independently and as part of a multidisciplinary team
• U.S. citizenship with the ability to obtain and maintain a DoD security clearance
• May require Moderate physical effort, including standing, sitting, and use of hands while performing duties, and carrying or lifting up to 50 pounds
• Working environment is indoor, moderately loud, reasonably clean, well-lit, and well-ventilated; moderate physical hazards may exist

Preferred Qualifications:

• 4 - 7 years of experience in production engineering, manufacturing engineering, or mechanical product development
• Experience designing for machining, sheet metal, welding, composites, or additive manufacturing
• Experience designing production tooling, fixtures, or assembly aids
• Experience supporting root cause analysis and corrective actions
• Familiarity with Engineering Change Requests (ECRs) and Engineering Change Notices (ECNs)
• Experience developing Technical Data Packages (TDPs) and work instructions
• Familiarity with ISO 9001 quality systems
• Experience using ERP or MRP systems
• Experience performing FEA using SolidWorks Simulation or COMSOL
• Familiarity with electronic assembly and ESD-controlled environments
• Experience managing multiple engineering projects simultaneously
• Active Secret or Top-Secret DoW security clearance

SARA offers a competitive benefits package to include:

• Medical, dental, vision, disability and life insurance; and other supplemental programs
• A generous PTO program (vacation, sick, holiday)
• Tuition & certification reimbursement
• Flexible work schedules
• Discretionary Employee bonuses
• 401(k) match/profit sharing
• Employee Stock Ownership Plan (ESOP)

Pay Range

Salary at SARA is determined by various factors, including but not limited to location, the individual's particular combination of education, knowledge, skills, competencies, and experience, as well as contract-specific affordability and organizational requirements. The projected compensation range for this position is $65,000 to $110,000 (Annualized USD). The estimate displayed represents the typical salary range for this position and is just one component of SARA's total compensation package for employees. Positions are on-site, unless indicated otherwise.

Application Deadline: October 26, 2026

SARA is an equal employment opportunity employer.