Senior Manufacturing Engineer

Senior Manufacturing Engineer - Heavy Fabrication & Vendor Surveillance

Location: Rockville, MD (On-site / Hybrid, 25%-50% domestic/international travel)

The Mission

Traditional aerospace and power generation projects can take decades to get off the drawing board. We are changing that. We are partnering with an advanced technology pioneer that is actively building and commercializing next-generation technology designed to provide clean, safe, and continuous power to heavy industry and the grid.
With major commercial backing and a clear path to deployment, our client is moving fast. We are looking for hands-on Senior Manufacturing Engineers who want to escape the bureaucracy of legacy engineering, get out of the office, and lead the physical fabrication of heavy hardware.

Why This Role is Different

On-the-Ground Execution: You will not be stuck behind a desk managing spreadsheets. You will spend up to 50% of your time traveling to partner facilities and fabrication shops, working directly on the factory floor with heavy manufacturers to bring massive, high-temperature structures to life.

Real-Time Problem Solving: When manufacturing issues arise on components, you will be the lead authority on-site. You will troubleshoot fabrication, welding, and assembly challenges in real-time to keep production moving.

Direct Impact: You will bridge the gap between design engineering and the actual shop floor, ensuring that complex, high-tolerance components are optimized for manufacturing and fabricated to the highest standards.

Position Summary

As a Senior Manufacturing Engineer, you are responsible for translating complex component designs into physical, manufactured products. This role requires deep expertise in heavy component fabrication, design for manufacturability (DFM), process optimization, and quality assurance. You will provide on-site surveillance, technical oversight, and leadership across our supplier network throughout the entire manufacturing lifecycle.

Key Responsibilities

• Drive the manufacturing, fabrication, and testing oversight of first-of-a-kind (FOAK) heavy components.
• Perform on-site vendor fabrication surveillance, ensuring suppliers adhere to design specifications and strict quality requirements.
• Collaborate with design teams to apply Design for Manufacturability (DFM) principles, translating supplier feedback back into the engineering models and drawings.
• Troubleshoot fabrication, welding, machining, and assembly issues in real-time, providing immediate engineering solutions to complex production problems.
• Guide component designs to accommodate non-destructive examination (NDE) accessibility constraints, especially in spatial limitations.
• Mentor and guide junior engineering team members, driving accountability and technical success across multiple concurrent projects.

Examples of Systems You Will Oversee

• Massive structural metal fabrications and assemblies
• Heavy pressure vessels and high-temperature piping systems
• High-temperature structural components (including specialized materials like graphite)
• Complex mechanical assemblies requiring precision machining, welding, and assembly

What We Are Looking For

• Hands-On Manufacturing: Demonstrated experience delivering complex hardware or manufacturing processes in a production environment (aerospace, defense, heavy machinery, or power generation).
• Heavy Component Fabrication Experience: Background in startup support, vendor management, and on-site surveillance for heavy industrial components.
• Codes & Standards: Strong familiarity with ASME Boiler and Pressure Vessel Code (BPVC) standards (such as Section III or VIII) and AWS welding standards.
• Welding & NDE Expertise: Deep knowledge of weld engineering, weld specifications, and Non-Destructive Examination (NDE) techniques.
• Technical Problem Solving: High proficiency in engineering hand calculations to assess structural, thermal, or fabrication issues on-site.
• Mobility: Ability and willingness to travel both domestically and internationally (typically 25%-50%) to partner facilities and fabrication shops.

Qualifications

• Bachelor's degree in mechanical engineering, aerospace engineering, or a related discipline from an accredited institution.
• Typically 5 to 15+ years of engineering experience, with a heavy emphasis on manufacturing, fabrication, or hardware ownership (master's or Ph.D. degrees may count toward experience years).

What is in it for You

You will have the opportunity to work at the edge of the clean energy transition. Our client offers highly competitive compensation, a comprehensive benefits package (medical, dental, vision, 401k match), robust professional development support, and a work culture where your engineering contributions are visible every day.

must be a U.S. citizen or permanent resident