Senior Electrical Engineer

CoAspire (https://www.coaspire.com) is a cutting-edge defense manufacturing leader in Northern Virginia, specializing in the precision assembly of advanced weapons systems. With over twelve years of a legacy of innovation, we're at the forefront of building reliable, affordable mass weapons that protect and empower our nation’s warfighters. Our tight-knit team thrives in a collaborative environment where safety, quality, and work-life balance come first with a focus on professional growth at our new 27,000 sq. ft. facility. Join us to make a tangible impact on mission-critical technology while enjoying Northern Virginia's vibrant community.

Position: You will work directly on the production floor and drive electrical/avionics assembly process optimization, cost reduction, and design-for-manufacturability improvements for weapon systems. You will identify and implement changes to wiring harnesses, connectors, circuit card assemblies (CCAs), power distribution, RF components, cables, and subsystems to reduce build time, lower material costs, eliminate production bottlenecks, and support affordable high-rate manufacturing — all while maintaining full compliance with government performance, EMI/EMC, environmental, and safety standards. This hands-on role works side-by-side with technicians, quality, procurement, and systems engineering to transition products from prototype/design models to sustained high-volume production.

Responsibilities:

• Lead electrical/avionics Design-for-Manufacturing/Assembly (DFM/DFA) reviews and value engineering initiatives to simplify harness designs, standardize connectors and components, reduce wire count/routing complexity, and minimize CCA variants.
• Identify and qualify lower-cost alternative connectors, cables, CCAs, power supplies, RF components, and electronics (COTS/mil-spec) that meet form/fit/function, EMI/EMC, environmental, and ITAR requirements while achieving cost savings.
• Optimize electrical assembly sequences, tooling, fixtures, work instructions, and test procedures to cut assembly and test time, reduce labor hours, and improve first-pass yield on the production line.
• Perform root-cause analysis on electrical production issues (harness fit/routing, continuity failures, EMI problems, non-conformances, rework) and implement corrective actions, including ECNs and schematic/redline updates.
• Collaborate with supply chain and suppliers on make-vs-buy decisions for harnesses/CCAs, vendor qualifications, obsolescence management, and long-term agreements to secure cost-effective, reliable sources.
• Support and maintain electrical manufacturing bills of materials (MBOMs), cable drawings, schematics, and test documentation in the ERP/PLM system.
• Conduct time studies, line balancing, and capacity analyses for electrical assembly and test stations; mentor technicians and junior engineers on the floor.
• Ensure all changes comply with AS9100D and all company and customer requirements.

Qualifications:

• 8 years of hands-on electrical/electronics manufacturing or production engineering experience in aerospace/defense.
• Bachelor’s degree in Electrical Engineering, Electronics Engineering, or related field.
• Experience of cost-reduction and assembly/test time improvement programs (e.g., harness simplification, connector standardization, CCA redesign-for-cost, COTS insertion).
• Strong ability to read and redline schematics, harness drawings, and PCB layouts; experienced releasing ECNs in PLM/ERP environments (e.g., Windchill).
• Strong knowledge of military-grade and/or COTS connectors, cable/harness fabrication (IPC/WHMA-A-620), RF/coaxial assemblies, power distribution, and EMI shielding techniques.
• Familiarity with electrical manufacturing processes including crimping, soldering, automated wire processing, conformal coating, and functional/ESS testing.
• U.S. citizenship and current Secret clearance (or ability to obtain/maintain one).
• Excellent communication and floor presence; comfortable presenting data-driven recommendations to leadership and suppliers.

Desired Skills:

• Master’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or Aerospace Engineering.

What We Offer:

Beyond competitive pay, we offer:

• Full benefits from day one: medical, dental and vision
• 401(k) with generous company match and immediate vesting
• PTO and Federal holidays

Apply now! We're reviewing applications on a rolling basis. Let's build the future together. No agencies, please.

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