SR. MANUFACTURING ENGINEER

ZipRecruiter; Littleton (CO); On-site; USD 90,000 - 130,000; Full time

Job summary

A leading company in aerospace and defense seeks a Senior Manufacturing Engineer with profound expertise in RF rotary joints. The successful candidate will be instrumental in process optimization, collaborating with design teams and ensuring quality standards. Candidates must hold a relevant bachelor's degree and possess extensive experience in manufacturing engineering, particularly in aerospace applications.

Qualifications

• Minimum of 7 years of manufacturing engineering experience.
• At least 2 years focused on precision RF/mechanical assemblies.
• U.S. Citizenship required due to ITAR and DoD contract regulations.

Responsibilities

• Develop and optimize manufacturing processes for RF rotary joints.
• Collaborate with engineering teams on manufacturability.
• Lead root cause analysis for quality issues.

Skills

RF specifications

Lean Six Sigma

Mechanical tolerances

Process control

Root cause analysis

Education

Bachelor’s degree in Mechanical Engineering

Bachelor’s degree in Electrical Engineering

Bachelor’s degree in Manufacturing Engineering

Tools

CAD (SolidWorks)

RF testing equipment

Job description

Job DescriptionJob DescriptionDescription:

Position Summary:

We are seeking a highly experienced Senior Manufacturing Engineer with specialized expertise in the production of RF rotary joints for aerospace and defense applications. The ideal candidate will lead the development and optimization of manufacturing processes for precision rotary joint assemblies used in radar systems, satellite communication, and electronic warfare platforms. This role requires deep understanding of RF performance considerations, mechanical tolerances, and process control in high-reliability, mission-critical products.

Key Responsibilities:

• Develop and optimize end-to-end manufacturing processes for RF rotary joints, including precision machining, plating, assembly, and RF performance validation.
• Collaborate with design and RF engineering teams to ensure manufacturability of new rotary joint designs and support Design for Manufacturability (DFM) and Design for Testability (DFT) efforts.
• Define and implement process controls and quality standards specific to rotary joint alignment, VSWR minimization, insertion loss, and signal integrity.
• Specify custom tooling, assembly fixtures, and automated solutions for high-precision mechanical and RF alignment tasks.
• Troubleshoot mechanical and RF-related manufacturing issues including contact resistance, axial/radial runout, and wear/lubrication failures.
• Lead root cause analysis (RCA) and corrective/preventive actions (CAPA) for internal and field quality issues.
• Support cleanroom and ESD-safe environments as necessary during subassembly and final integration.
• Drive continuous improvement initiatives using Lean, Six Sigma, and 5S principles to increase yield and reduce scrap/rework.
• Collaborate with RF design engineering to ensure production testing correlates with customer specifications and performance criteria.
• Maintain documentation including process flow diagrams, work instructions, routers per AS9100/ISO standards.

Requirements:

Qualifications:

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Manufacturing Engineering, or a related field.
• Minimum of 7 years of manufacturing engineering experience, with at least 2 years focused on precision RF/mechanical assemblies in aerospace or defense.
• Strong understanding of RF specifications, including insertion loss, VSWR, phase stability, and isolation.
• Proficient in CAD (SolidWorks ) and able to interpret GD&T and tolerance stack-up for rotating components.
• Familiarity with RF testing equipment (e.g., VNA, spectrum analyzers) and performance evaluation in a manufacturing environment.
• Familiarity with MIL-STD and AS9100 quality systems and ITAR regulations.
• Demonstrated experience with root cause analysis tools.
• U.S. Citizenship required (due to ITAR and DoD contract requirements).

Experience:

• Hands-on experience manufacturing waveguide rotary joints, coaxial rotary joints, or multi-channel RF/microwave assemblies.
• Knowledge of materials used in high-frequency and high-cycle applications (e.g., PTFE, beryllium copper, RF-compatible lubricants).
• Experience with hermetic sealing, environmental testing (e.g., thermal cycling, vibration), and ruggedized component design.
• Lean Six Sigma Green or Black Belt certification.
• Experience supporting satellite, radar, or maritime/airborne communication systems.

Work Environment & Physical Demands:

• Split between office and manufacturing floor (including cleanroom or controlled environments).
• Use of microscopes, calipers, torque tools, and RF diagnostic equipment.
• Occasional travel to suppliers, customers, or other company locations may be required.

Diamond Antenna & Microwave is an Equal Opportunity-Affirmative Action Employer – Minority / / / Veteran / / /