Senior Manufacturing Engineer - DFM

About Mainspring Mainspring Energy manufactures and delivers fuel-flexible, low-emissions local power solutions that rapidly add new capacity and deliver reliable, affordable, and sustainable electric power. The company began commercial shipments of its Mainspring Linear Generators in 2020 and today has hundreds of megawatts in advanced development and field operations for leading Fortune 500 companies, data centers, and utilities. Mainspring also partners with global energy leaders including AEP, NextEra Energy Resources, Schneider Electric, and more. The core values that ground our work, guide our decisions, and connect us together: Pragmatic Optimism Excellence without Ego Proactive Collaboration

Job Overview We are seeking a highly capable Manufacturing Engineer with a strong mechanical engineering foundation to bridge the gap between product design and scalable production. In this role, you will partner closely with Mechanical Design Engineering to ensure our products are not only functional, but manufacturable, scalable, and robust at volume. You will play a critical role in shaping design decisions early—driving DFM/DFX, tolerance strategies, and assembly error-proofing into the product architecture. This is not a downstream role. You will actively challenge and influence design concepts, ensuring they are suitable for high-volume production—not just prototype success. The ideal candidate combines strong mechanical design fundamentals with hands-on manufacturing experience and thrives in collaborative, fast-paced environments.

Design for Manufacturability (Core Focus): Partner with Mechanical Design Engineers to translate product concepts into manufacturable, scalable solutions

Drive DFM/DFX initiatives, including tolerance stack-ups (GD&T), datum strategy, and assembly sequencing

Convert assembly process learnings (error-proofing, access, ergonomics) into clear design requirements

Actively influence and challenge product design decisions using first-principles engineering and manufacturing constraints

Contribute to design decisions with understanding of stress, interfaces, and system integration

Assembly and Equipment design: Design and develop fixtures, jigs, and assembly equipment with a focus on precision, repeatability, and cost

Perform tolerance analysis and support detailed 2D drawing creation for fabrication

Support early validation through prototyping, testing, and iteration

Select and integrate actuators, sensors, and standard components; define functional sequences for automation

Emphasize simple, robust solutions using off-the-shelf components where possible

Manufacturing Scale-Up:

Own the transition of assembly processes from prototype builds to scalable production systems

Plan and validate production processes using PFMEA, DOE, and capability studies (Cpk, GR&R)

Collaborate cross-functionally with Quality, Supply Chain, and Operations to move from prototype to volume production

Support factory layout, line design, capacity planning, and continuous improvement efforts

Education and work experience:

Bachelor’s or Master’s degree in Mechanical Engineering or related field

5+ years of experience in mechanical design, manufacturing engineering, or a hybrid role

Strong foundation in:

Proficiency in CAD tools (e.g., SolidWorks, CATIA)

GD&T and tolerance stack-up analysis

2D drawing creation for manufacturing

Datum strategy and precision assembly

Demonstrated experience influencing product design for manufacturability

Experience designing assembly processes and scaling from prototype to production

Familiarity with:

PFMEA, 8D, DOE

Process capability (Cpk), GR&R

Assembly technologies (fastening, machining, laser metrology)

Willingness to travel internationally up to 15%

Ability to challenge design decisions with data and first-principles thinking

Strong intuition for “what will break at scale” vs. what works in prototype

Hands-on mindset—you’re comfortable on the floor validating your ideas

Bias for simple, cost-effective solutions over over-engineering

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