Senior Electronics Manufacturing Engineer (harnessing And Electronics)

Pivotal is the leader in the emerging market of electric Vertical Takeoff and Landing (eVTOL) aircraft. We design, develop, and manufacture light eVTOL aircraft and are renowned for the BlackFly, the first light eVTOL to fly manned missions and enter the consumer market.

Efficient, compact, and simple, Pivotal vehicles are designed for a wide range of consumer, public service, and defense applications. Our distinctive tilt-aircraft architecture and scalable platform have been in development, preparing to enter the market for over 10 years. We recently announced our next-generation aircraft, the Helix, planned for general release and scalable production in early 2025.

Mobility is one of the most highly-valued areas of technology investment today. This is the right company, in the right space, the right strategy, at the right time. We invite you to join our amazing team and grow with us.

The Senior Electronics Manufacturing Engineer will lead the assembly, testing, and integration of wire harnesses and printed circuit board assemblies (PCBAs) for both R&D and production of EVTOL aircraft. This role involves partnering closely with design engineering teams to ensure a robust design process, facilitating seamless and high-quality production of harnesses and PCBAs. You will take ownership of manufacturing processes, including overseeing contract manufacturers and managing internal production teams to deliver aerospace-grade harnesses and PCBAs. This includes responsibility for all factory-floor processes, tooling, and continuous improvement initiatives.

Additionally, you will provide strategic oversight for integration planning and operations, including vehicle routing, harness installation, and electrical connections. You will serve as a key technical leader, guiding production and integration efforts while maintaining a relentless focus on quality and precision.

The ideal candidate brings extensive experience in aerospace harness and PCBA manufacturing, a proven track record of establishing and sustaining production processes with an emphasis on quality and reliability, and meticulous attention to detail. If leading end-to-end manufacturing for space-bound systems, driving innovation, and taking ownership of mission-critical hardware excites you, this is the role for you.

Responsibilities

Cable Harnessing

• Design, optimize, and validate cable harness manufacturing processes, ensuring compliance with industry standards (e.g., IPC/WHMA-A-620)
• Collaborate with design and engineering teams to ensure manufacturability of cable harness assemblies
• Develop detailed work instructions, tooling, harnessing form boards and testers, process flow diagrams, and quality control plans for cable harness assembly
• Troubleshoot production issues and implement corrective actions to meet quality and delivery targets
• Work with harnessing suppliers to resolve build and timeline issues and ensure the product meets safety and quality standards

Electronics Manufacturing Support

• Provide engineering support for the assembly and testing of PCBAs, batteries, and related electronic components
• Collaborate with suppliers to resolve technical challenges and improve component reliability
• Contribute to the design-for-manufacturing (DFM) and design-for-testability (DFT) initiatives for electronic assemblies

Process Improvement and Optimization

• Implement Lean Manufacturing principles to improve process efficiency, reduce waste, and enhance productivity
• Conduct time studies, capacity analysis, and root cause analysis to support continuous improvement initiatives
• Lead efforts to implement advanced manufacturing technologies and automation solutions

Compliance and Documentation

• Ensure all manufacturing processes comply with relevant aerospace and industry standards
• Maintain detailed documentation, including engineering change orders (ECOs), work instructions, and process validation reports.
• Support audits and certifications related to AS9100, ISO9001, and other quality systems

Cross-Functional Collaboration

• Partner with design, quality, and supply chain teams to address production challenges and ensure seamless transitions from prototype to full-scale production
• Experience with Design for Manufacturability (DFMA) of electronics and harnessing hardware
• Train and mentor production staff and junior engineers on best practices and technical skills with regards to cable harnessing and electronics

Required Qualifications

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Electrical Engineering, or a related field
• 5+ years of hands-on experience in manufacturing engineering, with a focus on cable harnessing and electronics assembly
• Deep understanding of materials used in harness and PCBA manufacturing, including wire types, connectors, epoxies, PCB design considerations, electrical components, board conformal coating materials and application methods, and soldering techniques for various applications
• Worked in an R&D environment bringing a product from concept to production
• Experience successfully tackling multiple high-priority tasks
• Aerospace or defense industry experience is strongly preferred
• Proficiency in CAD software (e.g., 3DX Systems, Catia v5) and harness design tools
• Familiarity with industry standards such as IPC/WHMA-A-620, IPC-A-610, J-STD-001, SAE AS 50881 and AS9100
• Experience with process validation tools such as PFMEA, SPC, and Control Plans

Bonus Qualifications

• Master’s degree in related discipline, Aerospace Engineering, Mechanical Engineering, Electrical Engineering etc
• IPC-620 certification
• Interested in working in the eVTOL industry
• Knowledge of Part 103 requirements
• Basic programming or scripting skills for automation and testing equipment is a plus

Soft Skills

• Brings positive attitude and energy to the workplace
• Strong analytical and problem-solving abilities
• Excellent verbal and written communication skills
• Ability to work in a fast-paced, collaborative environment
• Demonstrated leadership and project management capabilities