DFM Electrical Engineer, Senior

Description:Position: Senior DFM Electrical EngineerDepartment: EngineeringLocation: Santa Ana, CA FLSA Status: Exempt, Full-TimeJob Summary:The Senior DFM Electrical Engineer leads all electrical Design for Manufacturability (DFM) activities across Brandywine’s electronic product portfolio. This position ensures that printed circuit board assemblies (PCBAs) and electrical designs are optimized for manufacturability, cost efficiency, and quality before release to production or external EMS providers. The role serves as the bridge between design engineering and manufacturing, with responsibility for mitigating product obsolescence risks, refining existing designs for long-term sustainability, and ensuring a smooth transition from prototype to production.Key Responsibilities:· Perform DFM reviews for all existing and new PCB assemblies, ensuring manufacturability, reliability, and cost optimization prior to release.· Lead DFM activities for the board-level product obsolescence program, addressing high-risk components and identifying replacement or redesign options.· Partner with design engineers to review schematics, layouts, and BOMs for compliance with internal and industry standards.· Develop and maintain DFM guidelines for electrical design, incorporating feedback from internal teams and EMS partners.· Collaborate with manufacturing and supply chain teams to ensure component availability, standardization, and ease of assembly.· Perform recurring obsolescence evaluations and implement component or layout updates for existing products.· Validate that designs meet fabrication (DFF) and assembly (DFA) requirements, optimizing PCB layout for solderability, spacing, and accessibility.· Evaluate and approve design documentation packages for production readiness, including Gerber files, fabrication drawings, and test procedures.· Work with suppliers and EMS providers to align design specifications with manufacturing capabilities and process limits.· Contribute to continuous improvement by identifying cost-reduction opportunities and design simplifications that improve product yield and throughput.· Provide technical leadership in DFM methodology, training, and best practices across the engineering team.Required Qualifications:· Bachelor’s degree in Electrical Engineering or a closely related field.· Minimum of 8 years of professional experience in PCB design, DFM, or electronic product development within aerospace, defense, or high-reliability manufacturing.· Demonstrated experience performing DFM and DFA reviews and implementing design improvements based on manufacturability feedback.· Proven ability to analyze and modify electrical designs to meet manufacturing, cost, and quality goals.· Proficiency in PCB design tools (e.g., Altium Designer, OrCAD, or Mentor Graphics) and design documentation review.· Strong understanding of component lifecycle management and product obsolescence mitigation.· Knowledge of industry standards such as IPC-A-600, IPC-610, and MIL-STD design guidelines.· Demonstrated ability to manage multiple concurrent projects with attention to detail and deadlines.· Effective communication skills for cross-functional collaboration with design, manufacturing, and supply chain teams.Preferred Qualifications:· Master’s degree in Electrical or Electronics Engineering.· Experience working directly with EMS or CEM providers in a design-to-production environment.· Hands-on experience with PLM/ERP systems for managing design data and component lifecycles.· Familiarity with AS9100 and ITAR/EAR compliance requirements.· Experience designing for automated test and inspection processes (DFT/AOI/ICT).Physical Requirements:· Must be able to sit or stand for extended periods and frequently perform tasks that require repetitive motion, such as typing on a keyboard or using design software.· Regular use of a computer, telephone, and headset is required, including participation in virtual meetings via Microsoft Teams.· Ability to visually inspect PCB layouts, schematic diagrams, and fine electronic components.· Must be able to lift up to 25 lbs occasionally when handling prototypes or lab equipment.· Follow established safety and quality protocols in a fast-paced production/manufacturing environment, including the use of ESD protection when handling electronic components.· This is primarily an office-based role located within a shared open-concept office inside a warehouse facility. The work environment may include elevated noise levels due to open workspaces and conversational noise. Employees should be comfortable working in a setting where sound carries and interruptions may occur.Security Clearance Eligibility:Some positions at Brandywine Communications may require the ability to obtain and maintain a U.S. Department of Defense (DoD) security clearance. While not all roles require an active clearance at the time of hire, applicants must be eligible for clearance under federal guidelines, and employment may be contingent upon successful completion of a government background investigation.Equal Opportunity Employer Statement:Brandywine Communications is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all employees and applicants without regard to race, color, religion, sex, (including pregnancy, childbirth, and related medical conditions), sexual orientation, gender identity or expression, national origin, ancestry, age, physical or mental disability, medical condition, genetic information, marital status, military or veteran status, or any other characteristic protected by federal, state, or local laws.Brandywine Communications strives to create a workplace that is inclusive, respectful, and reflective of the diverse communities we serve. We are committed to providing reasonable accommodations for qualified individuals with disabilities in accordance with applicable laws. If you require accommodation during any part of the application or hiring process, please contact the Human Resources department. Requirements: