Principal Automation Engineer, Controls

Mach Industries; Huntington Beach (CA); On-site; USD 180,000 - 260,000; Full time

Job summary

Mach Industries seeks a Principal Automation Engineer, Controls to own the architecture, development, and deployment of our factory controls platform, establishing Beckhoff TwinCAT as the standard and leading pilot line automation.

You will design, program, integrate, and commission equipment for $20M+ automation programs, scaling architectures with external integrators. This is a hands-on leadership role spanning architecture to Run at Rate.

Qualifications

• Experience owning controls architecture and development for factory automation.
• Pilot manufacturing line design, programming, and commissioning experience.
• Knowledge of safety PLCs, machine safety, interlocks, guarding, and safety validation.
• Ability to lead systems integrators on large automation capital programs and define acceptance criteria.

Responsibilities

• Own Mach's factory controls architecture and technical roadmap, standardized around Beckhoff TwinCAT.
• Define standards for PLC software, Beckhoff IPCs, EtherCAT I/O, motion control, industrial networks, machine safety, diagnostics, and factory interfaces.
• Develop reusable TwinCAT software libraries, machine state models, fault handling, recovery strategies, and programming standards.
• Own controls and functional-safety architecture, including safety PLCs, safe motion, interlocks, guarding, emergency stops, and safety validation.
• Personally design, program, integrate, and commission automation equipment for pilot manufacturing lines.
• Translate successful pilot architectures into scalable equipment standards and specifications for production systems.
• Develop controls requirements, Statements of Work, design standards, and acceptance criteria for externally integrated equipment.
• Serve as the controls technical lead for systems integrators executing $20M+ automation programs.
• Lead technical design reviews across electrical systems, PLC software, robotics, motion, networking, machine safety, and factory interfaces.
• Lead controls execution through FAT, SAT, installation, commissioning, and production launch.
• Troubleshoot complex interactions between PLCs, robotics, motion systems, machine vision, instrumentation, safety systems, and factory software.
• Optimize machine sequences, cycle time, fault recovery, reliability, and OEE during production ramp.

Skills

Beckhoff TwinCAT

PLC programming

Controls architecture

Industrial automation

System integration

Safety systems

Production commissioning

Tools

Beckhoff TwinCAT

EtherCAT

Job description

About Mach Industries

Founded in 2023, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 350 employees, we operate with startup agility and ambition.

About Mach Industries

Founded in 2023, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 350 employees, we operate with startup agility and ambition.

Our vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security.

The Role

Mach Industries is seeking a Principal Automation Engineer, Controls to own the architecture, development, and deployment of our factory controls platform.

You will establish Beckhoff TwinCAT as Mach's standardized controls platform, personally develop automation equipment for pilot production lines, and scale those architectures through external systems integrators executing $20M+ capital equipment programs.

This is a hands‑on technical leadership role. You will be expected to move between defining controls architecture and standards, writing and debugging production code, reviewing integrator designs, commissioning equipment on the factory floor, and solving problems during production ramp.

Your ownership extends from initial controls architecture through FAT, installation, commissioning, and Run at Rate.

Key Responsibilities

• Own Mach's factory controls architecture and technical roadmap, standardized around Beckhoff TwinCAT.
• Define standards for PLC software, Beckhoff IPCs, EtherCAT I/O, motion control, industrial networks, machine safety, diagnostics, and factory interfaces.
• Develop reusable TwinCAT software libraries, machine state models, fault handling, recovery strategies, and programming standards.
• Own controls and functional-safety architecture, including safety PLCs, safe motion, interlocks, guarding, emergency stops, and safety validation.
• Personally design, program, integrate, and commission automation equipment for pilot manufacturing lines.
• Translate successful pilot architectures into scalable equipment standards and specifications for production systems.
• Develop controls requirements, Statements of Work, design standards, and acceptance criteria for externally integrated equipment.
• Serve as the controls technical lead for systems integrators executing $20M+ automation programs.
• Lead technical design reviews across electrical systems, PLC software, robotics, motion, networking, machine safety, and factory interfaces.
• Lead controls execution through FAT, SAT, installation, commissioning, and production launch.
• Troubleshoot complex interactions between PLCs, robotics, motion systems, machine vision, instrumentation, safety systems, and factory software.
• Optimize machine sequences, cycle time, fault recovery, reliability, and OEE during production ramp.