Staff Manufacturing Engineer

ExoTerra Resource; Littleton (CO); On-site; USD 135,000 - 160,000; Full time

Job summary

ExoTerra is seeking a Staff Manufacturing Engineer to drive scalable, high-rate production of space hardware. You will own manufacturing strategy, production readiness, and process excellence across programs.

You will lead AI&T, DFx, and continuous improvement, partner with design, quality, and supply chain, and mentor engineers on robust, repeatable manufacturing. This role requires aerospace expertise, AS9100 familiarity, and hands-on leadership on the factory floor to resolve complex issues

Qualifications

• Bachelor's degree in Mechanical, Manufacturing, Aerospace Engineering, or related field.
• 8-15 years of experience in manufacturing engineering, with aerospace/space hardware production.
• Deep expertise in AI&T, DFM/DFA/DFT, and production system design.
• Extensive experience with non-conformance resolution and root cause methodologies.
• Strong familiarity with AS9100, GD&T, and aerospace quality standards.

Responsibilities

• Act as end-to-end manufacturing owner for complex parts, assemblies, and products across programs.
• Define and implement manufacturing strategies for high-rate production, cost targets, and delivery schedules.
• Drive production scalability, capacity planning, and line balancing to meet increasing build rates.
• Lead AI&T activities, testing methodologies, and repeatable integration processes.
• Provide design-for-manufacturing input during reviews (PDR, CDR, MRR, TRR).
• Develop robust manufacturing processes, tooling, fixtures, and automation solutions.
• Lead continuous improvement using Lean, Six Sigma, and advanced manufacturing techniques.
• Oversee NCR investigations, root cause analyses, and MRB disposition strategies.
• Ensure data capture, traceability, and configuration control in production docs.
• Provide hands-on leadership on the factory floor and resolve complex build issues.
• Coordinate with procurement and supply chain to align material availability with demand.

Skills

AI&T

DFM

DFA

DFT

Root cause methodologies

Education

Bachelor's degree in Mechanical, Manufacturing, Aerospace Engineering, or related field

Job description

Company Overview

ExoTerra is a world leader in solar electric propulsion systems and space exploration satellites. The company develops Hall Thrusters, propulsion modules, microsatellites and launch vehicle upper stages. We have been awarded multiple propulsion module and satellite contracts.

Position Summary

The Staff Manufacturing Engineer serves as a technical leader and manufacturing authority responsible for enabling scalable, high-rate production of space hardware across multiple programs. This role drives manufacturing strategy, production readiness, and process excellence while ensuring products meet stringent aerospace quality and reliability standards.

This position requires deep expertise in production system design, Assembly Integration \& Test (AI\&T), and cross-functional leadership, with a strong focus on transitioning complex hardware from development into repeatable, high-volume manufacturing.

Essential Functions:

Manufacturing Ownership & Production Strategy

• Serve as the end-to-end manufacturing owner for complex parts, assemblies, and products across multiple programs
• Define and implement manufacturing strategies to support high-rate production, cost targets, and delivery schedules
• Drive production scalability, capacity planning, and line balancing to meet increasing build rates

AI&T Leadership

• Lead the planning, development, and execution of Assembly, Integration \& Test (AI\&T) activities, including mechanical systems and module-level testing
• Establish standardized integration and test methodologies to improve repeatability, efficiency, and throughput

Design for Manufacturing Leadership

• Provide authoritative manufacturing input during design phases and formal reviews (PDR, CDR, MRR, TRR)
• Drive DFM/DFA/DFT initiatives, influencing design decisions to optimize producibility, cost, and performance
• Approve and sign off on engineering drawings and configurations for manufacturing readiness

Process Development & Continuous Improvement

• Architect and implement robust manufacturing processes, including tooling, fixtures, and automation solutions
• Lead continuous improvement initiatives leveraging Lean, Six Sigma, and advanced manufacturing techniques
• Establish and monitor key performance indicators (KPIs) such as yield, cycle time, OEE, and first-pass yield (FPY)

Quality & Non-Conformance Leadership

• Lead and participate in non-conformance investigations (NCR), driving root cause analysis (RCA) and corrective actions
• Serve as a senior member of the Material Review Board (MRB), setting disposition strategies and quality standards
• Ensure full compliance with customer, regulatory, and aerospace quality requirements

Documentation & Manufacturing Systems

• Oversee the development and approval of manufacturing plans, travelers, SOPs, and control documentation
• Ensure complete and accurate data capture, traceability, and configuration control in all production documentation

Production Floor Leadership

• Provide hands-on leadership on the production floor, resolving complex build issues and removing barriers to execution
• Oversee manufacturing orders (MOs) and ensure alignment between production, engineering, and quality teams

Supply Chain & Inventory Integration

• Partner with Procurement and Supply Chain to ensure material availability aligns with production demand
• Oversee inventory planning, tracking, inspection, and verification processes for production readiness
• Manage risks related to material shortages, supplier performance, and lead times

Mentorship & Technical Leadership

• Mentor and develop engineers and technicians, elevating team capability and manufacturing discipline
• Set technical direction and best practices for manufacturing engineering across programs
• Act as a go-to subject matter expert (SME) for complex manufacturing challenges

Basic Qualifications

• Bachelor's degree in Mechanical, Manufacturing, Aerospace Engineering, or related field
• 8-15 years of experience in manufacturing engineering, with significant experience in high-reliability or aerospace/space hardware production
• Demonstrated success scaling products from development into high-rate production
• Deep expertise in AI\&T, DFM/DFA/DFT, and production system design
• Extensive experience with non-conformance resolution and root cause methodologies
• Strong familiarity with AS9100, GD\&T, and aerospace quality standards

Preferred Qualifications

• Excellent verbal and written communication skills
• Experience with Spacecraft Fabrication and Test
• Experience with non-conformance resolution
• Experience with manufacturing process development
• Experience with Programming

Export Control / Compliance Requirements

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Compensation & Benefits

The good faith base salary range (OR hourly range) for this role is $135,000-$160,000 at the time of this posting. Where you fall within the range depends on your experience, skills, and location. This range reflects base salary only and does not include benefits or bonus/incentive. This range may be adjusted in the future.

ExoTerra offers a comprehensive, total compensation package, which includes competitive salary, a discretionary annual bonus plan, paid time off (PTO), a comprehensive health benefit package and various other benefits. When you join our team, you're not just an employee; you become part of a dynamic community dedicated to innovation and excellence.

Equal Employment Opportunity Statement

ExoTerra is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.