Lead Manufacturing Engineer

MORSE Corp; Cambridge (MA); On-site; USD 120,000 - 150,000; Full time

Job summary

MORSE Corp is seeking a Lead Manufacturing Engineer to drive manufacturing scale for new prototypes and ramp up production of existing designs. You will collaborate with the CTO of Manufacturing and project teams to establish in-house capabilities, ensure quality, and identify new opportunities for manufacturing improvements.

The role emphasizes DfM/DFx, process optimization, and cross-functional leadership across mechanical, electrical, and vendor teams in a fast-paced environment.

Qualifications

• US citizenship required and the ability to obtain a U.S. Security Clearance.
• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering or another relevant Engineering degree.
• Proven ability to coordinate among multiple shifting priorities in a dynamic environment.

Responsibilities

• Scale manufacturing processes from R&D prototype builds to higher volume and fieldable manufacturing.
• Interface with design engineers during product development for DfM & DfA to ensure smooth transition to manufacturing.
• Create, evaluate, and improve manufacturing processes using knowledge of design, fabrication, assembly, tooling, and materials.
• Develop and document manufacturing procedures, work instructions, setup sheets, safety processes, routers, inspection points, and QC documentation.
• Define and implement manufacturing processes including PFMEA, equipment definition, layout planning, startup, qualification, and training.
• Work with technicians to ensure processes are followed and safe.
• Identify and implement process improvements for yield, quality, throughput or other KPIs.
• Perform root cause analysis and provide corrective/preventative actions.
• Complete QA/acceptance testing and develop QA processes for efficient manufacturing.
• Create functional specs for equipment and processes.
• Source, qualify, and select vendors for equipment and services.
• Collaborate with vendors to design, procure, and fabricate equipment and tooling.
• Coordinate with contract manufacturers to ramp up production of new systems and sub-assemblies.

Skills

Coordination

Cross-functional comms

DFM/DFMA

SolidWorks

3DEXPERIENCE

Lean manufacturing

Root Cause Analysis

PFMEA

ISO9001

ERP/MRP

BOM management

Education

Bachelor’s degree in Mechanical/Manufacturing Engineering

Tools

SolidWorks

3DEXPERIENCE

Job description

MORSE Corp is an employee owned, small business based in Cambridge, MA, Arlington, VA, and Seattle, WA with a history of fielding cutting‑edge technology. MORSE boasts a specially selected team of scientists, engineers, and software developers to deliver best‑in‑class technical solutions that solve difficult multidisciplinary problems faced by the US National Security Ecosystem.

MORSE is passionate about fielding technology to our users and to field more effectively, we are standing up new in‑house production capabilities. In this new role, you’ll be in at the ground level helping build and shape what manufacturing means at MORSE. You will drive tangible, high‑impact efforts. As a Lead Manufacturing Engineer, you will participate with the production of new product prototypes as well as manufacturing ramp up on existing and new designs. You will play a critical role helping MORSE set up new production lines for novel technologies. You will collaborate closely with the CTO of Manufacturing and project teams to identify new in‑house manufacturing capabilities, work with both internal and external partners to support projects, drive quality, and find innovative ways to achieve manufacturing goals.

RESPONSIBILITIES

• Scale manufacturing processes from R&D prototype builds to higher volume and fieldable manufacturing
• Interface with mechanical and electrical design engineers during product development for DfM & DfA considerations, to ensure a smoother transition to manufacturing
• Create, evaluate, and improve manufacturing processesapplying knowledge of product design, fabrication, assembly, tooling, and materials
• Develop and document manufacturing procedures, work instructions, setup sheets, safety processes, routers, inspection points, and QC documentation
• Develop and implement manufacturing processes including process definition, PFMEA, equipment definition and selection, layout planning, integration coordination, startup, qualification, and training
• Work with technicians to ensure manufacturing processes are being followed and implemented correctly and safely.
• Identify and implement process improvements for yield, quality, throughput, or other KPI as appropriate
• Utilize analytical skills to perform root cause investigation analysis and provide recommendations for corrective and preventative actions
• Employ QA skills to complete acceptance testing, identify & prevent production defects, and develop QA processes for efficient manufacturing
• Create functional requirements specifications for equipment and processes
• Source, qualify, and select vendors for equipment and contracted services
• Collaborate with vendors to design, procure, and fabricate equipment, tooling, fixtures, and supplies as needed
• Coordinate with contract manufacturing partners to ramp up production of new systems & sub‑assemblies

SKILLS AND REQUIREMENTS

• US CITIZENSHIP REQUIRED and the ability to obtain a U.S. Security Clearance
• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering or another relevant Engineering degree
• Proven ability to coordinate among multiple shifting priorities and flourish in a dynamic environment.
• Strong communication skills to bridge the gap between design engineers (ME/EE) and manufacturing vendors, ensuring design intent matches production capabilities.
• Fluent in SolidWorks & 3DEXPERIENCE (3DX) for the design, documentation, and lifecycle management of parts, large assemblies, drawings, and metadata.
• Experience optimizing designs for common manufacturing processes (sheet metal fabrication, CNC machining, welding, injection molding) and creating clear, visual Work Instructions (WIs) and SOPs.
• Ability to design and implement assembly jigs, fixtures, and Go/No-Go inspection gauges to ensure repeatable, high‑yield production.
• Practiced in LEAN manufacturing and Root Cause Analysis (RCA) principles with a history of ownership and execution of process improvement projects.
• Experienced with quality management systems (ISO9001), including document control, ECN/ECO processes, PPAP, NPI gates, and conducting PFMEAs to mitigate production risks.
• Proficient in GD&T (ASME Y14.5 standards), drawing reviews, and performing tolerance stack‑up analyses to ensure parts fit consistently during assembly.
• Experience utilizing ERP/MRP systems to manage Bills of Materials (BOMs), establish manufacturing routings, and support
• Ability to travel as required, up to 10%.

MORSE Corp’s salary range for this role carefully considers a wide range of compensation factors, including but not limited to, prior experience, education, skills and expertise, location, internal equity, and other factors that are job related and consistent with business need. Therefore, final offer amounts may vary from the amount stated. Depending on role eligibility, total compensation may also include bonus, stock, 401(k) match, paid time off, medical, dental, vision and life insurance.Employees also receive 10 paid holidays per year. MORSE maintains an “open” leave policy that does not restrict exempt, regular full‑time employees to a specificnumber of paid sick or vacation days. However, this policy is not an “unlimited” paid leave policy.

Compensation: $120,000 USD - $150,000 USD

The team at MORSE takes pride in being the smart team that is easy to work with. We focus on steady, long‑term success with an emphasis on exceptionalism and delivering mission‑critical impact to our customers. For more information, please visit www.morsecorp.com.