Senior Staff Manufacturing Engineer

We are looking for a talented Senior Staff Manufacturing Engineer to support production and NPI programs, helping to transform groundbreaking research prototypes into reliable, scalable systems for manufacturing and field deployment.

As a Senior Staff Manufacturing Engineer at Boston Dynamics, you will help build and enhance our development plant's manufacturing systems that enable predictable production outputs. As part of the Manufacturing Engineering team, you work on introducing changes to our robots, stabilizing and ramping up production while also managing the continuous improvement of the production of our products. Every day, you will collaborate with our Quality, Test, and OPM teams to define and understand blocking production problems and create and execute solutions to those problems.

To thrive in this role, you must have experience in and be excited by fast‑paced New Product Introduction environments and be highly motivated to drive efficiency and stability at all costs.

How You Will Make An Impact

• Develop, optimize, and implement manufacturing processes and assembly workflows for Spot, Stretch, and future robotics projects, from prototype through production.
• Define and drive the overall Manufacturing and Assembly strategy (DFM/DFA) across multiple product lines and NPI programs, acting as the technical authority to ensure designs are reliable, scalable, and serviceable.
• Design, fabricate, and validate custom fixtures, tools, and jigs to support mechanical assembly, precision alignment, and testing of electric motors and actuators, ensuring ergonomic and repeatable processes.
• Define assembly sequences, work instructions, and process documentation, including standard operating procedures (SOPs), visual aids, and training materials for assembly technicians.
• Support prototype builds in a hands‑on capacity, troubleshooting assembly issues, identifying root causes, and driving corrective actions to improve processes and product designs.
• Implement process controls to ensure build quality, dimensional accuracy, and alignment with product performance requirements.
• Establish and champion the continuous improvement efforts, leveraging Lean Manufacturing and Six Sigma to drive fundamental process improvements across the entire manufacturing system, resulting in measurable long‑term gains in efficiency and yield.
• Drive tooling and equipment validation, ensuring custom fixtures and tools are fully qualified for use in production, including performing capability studies where necessary.
• Act as a technical leader and mentor within the Manufacturing Engineering team, coaching junior and staff engineers and setting the technical bar for process development and high‑impact problem resolution.

You Bring

• Bachelor’s degree in Manufacturing, Mechanical, Industrial, Electrical Engineering, or a related field; Master’s degree a plus.
• At least 8-10 years of progressive experience in manufacturing engineering, process development, or advanced manufacturing, with a focus on strategic and systems‑level problem solving, preferably in robotics, aerospace, or complex electromechanical systems.
• Proven experience delivering industrial engineering outputs, such as capacity models, detailed line layouts, and value stream maps, to influence facility planning and strategic production goals.
• Expert in CAD software (SolidWorks, CATIA, or similar) for tool/fixture design and review of engineering drawings and strong understanding of GD&T (Geometric Dimensioning & Tolerancing).
• Experience with creating and approving change orders associated with products, procedures, and BOMs.
• Proven track record of DFM/DFA collaboration with design teams to drive manufacturable and serviceable product designs.
• Hands‑on experience with additive manufacturing, rapid prototyping, machining (e.g., Mill, Lathe) and fabrication (e.g., Welding, Grinding, Bending) techniques for developing and validating custom tooling, jigs, and fixtures to support precision mechanical assembly.
• Experience writing clear, concise, and detailed work instructions, SOPs, and training materials for assembly technicians.
• Experience working in production environments, with an ability to adapt processes for continuously evolving product designs.
• Demonstrated experience applying Lean Manufacturing, Six Sigma, and root cause analysis methodologies to drive process improvement.
• Excellent problem‑solving skills with the ability to troubleshoot complex mechanical and electromechanical assemblies.
• Strong communication and influencing skills, with a proven ability to present and defend complex technical concepts to senior leadership and negotiate trade‑offs with cross‑functional partners.
• Experience supporting on‑site prototype builds and providing direct manufacturing floor support – balancing countermeasures and corrective actions.

Nice To Have

• Experience supporting robotics development programs, particularly New Product Introduction (NPI).
• Experience with Product Lifecycle Management (PLM) systems for engineering change control and manufacturing documentation management (e.g., Arena, Enovia).
• Experience with Manufacturing Execution Systems (MES)/Platforms (e.g., Tulip, Delmia).
• Experience working in a research‑to‑product transition environment, where designs and processes evolve rapidly.
• Experience in design for mass production of multi‑part products and assemblies [DFM, DFA].
• Working experience with quality processes and systems (process control, 8D and other RCCA frameworks, etc.).

We are interested in every qualified candidate who is eligible to work in the United States. However, we are not able to sponsor visas for this position.

The salary or hourly pay range for this position will be clearly stated in the job posting as required by Massachusetts law. The base pay range for this position is between $135,000.00– $157,000. Base pay will depend on multiple individualized factors including, but not limited to internal equity, job related knowledge, skills and experience. This range represents a good faith estimate of compensation at the time of posting.