Senior Design For Manufacturing Engineer

HALCON is a regional and international leader that Offers Next-Generation Weapons Systems and Robotics Expertise to Meet the Challenges of a Rapidly Changing World.

Halcon mission is to bring innovative technologies to revolutionize the defence industry, through offering next-generation weapons systems and robotics expertise to meet the challenges of a rapidly changing world.

We design, manufacture, assemble and integrate components for gravity-release guided systems, missiles and loitering munitions.

Accountabilities:

This position is based in our workshop in Tawazun Industrial Park – Abu Dhabi.

The Senior design for Advanced Manufacturing Engineer participates in the design, development , qualification and production optimization processes, considering product design requirements, functionality, manufacturability, assembly, and automation.

Duties and Responsibilities:

• Design PCBs to integrate seamlessly with mechanical systems, electrical harnesses, and electronic modules, ensuring compliance with IPC Class 3 standards for high-reliability applications such as aerospace and defense.
• Develop PCB layouts optimized for automated manufacturing processes, supporting both low-volume prototyping and high-volume production. Ensure compatibility with Surface Mount Technology (SMT), Through-Hole Technology (THT), and automated assembly lines.
• Engage in the entire product development lifecycle, from concept generation and schematic design to PCB layout, prototyping, validation, qualification, and industrialization for manufacturing.
• Conduct Failure Mode and Effects Analysis (FMEA) for PCB designs to identify potential failure points during production or operation. Perform impedance and tolerance analyses to ensure manufacturability and scalability, minimizing defects and improving yield.
• Perform Signal Integrity (SI) and Power Integrity (PI) simulations to ensure the reliability of high-speed signals and power delivery networks in PCBs. Use tools like HyperLynx, Altium Designer, or Cadence Sigrity for analysis and optimization.
• Analyze PCB designs for thermal performance and mechanical stresses using tools such as ANSYS or Mentor Graphics FloTHERM, ensuring that the design can withstand high temperatures, vibration, and other harsh environmental conditions.
• Ensure PCBs are designed for efficient Automated Optical Inspection (AOI), X-ray inspection, and functional testing. Develop test points and strategies to enable high coverage during production.
• Ensure all PCB designs comply with IPC Class 3 standards, EMI/EMC guidelines, and relevant industry or regulatory standards (e.g., MIL-STD-461 for electromagnetic compatibility).
• Work closely with mechanical, electrical, software engineers to ensure PCB designs are manufacturable, testable, and integrated seamlessly within the larger system.
• Analyze design and production data (e.g., Gerber files, BOMs) to ensure quality and identify areas for improvement. Conduct root cause analysis for any production or performance issues, providing solutions for future iterations.
  
  

• 8+ years minimum of experience in Design for Manufacturing engineering in the automotive, defence or aerospace field.
• Bachelors or masters degree in electrical design engineering, or Manufacturing Engineering.
  
  

• Analytical thinking
• Comprehensive understanding of Surface Mount Technology (SMT), Through-Hole Technology (THT), wave soldering, reflow processes.
• Familiarity with PCB base materials (FR4, polyimide, ceramic), surface finishes (ENIG, HASL, OSP), and conformal coating processes used in high-reliability environments
• Deep understanding of IPC Class 3 standards and related guidelines (e.g., IPC-6012, IPC-610) to ensure PCBs meet high-reliability requirements.