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Powell Research and Development is hiring a Senior Design for Manufacture (DFM) Engineer in Southeast Houston. This role is intentionally designed to recognize either formal engineering education with experience OR extensive hands-on CNC machining expertise as equally valuable pathways to success.

As a Senior DFM Engineer, you will be a core member of the Research and Development Team, working alongside New Product Development Engineers, Manufacturing Engineers, and production teams to ensure new designs are manufactural, cost-effective, and production-ready. This position bridges design intent and shop-floor reality and plays a critical role in scaling designs from prototype to full production.

This position does not allow for sponsorship support.

Job Description

• Collaborate with cross-functional engineering, manufacturing, and machining teams to ensure robust DFM/DFA/DFX, throughout the product lifecycle.

• Review parts and assemblies with a strong focus on machinability, tolerancing, fixturing, tooling access, and assembly efficiency.

• Identify manufacturability, machining, and assembly risks early and provide clear, actionable design recommendations.

• Translate design intent into practical, repeatable manufacturing solutions, informed by real-world machining capability.

• Ensure product manufacturing and assembly requirements are clearly understood by production teams.

• Support new product development by evaluating and improving machining methods, tooling strategies, fixtures, and work holding concepts.

• Improve manufacturing efficiency by helping to analyze and plan workflow, space requirements, and equipment layout.

• Assures product and process quality by helping to design testing methods; testing finished- product and process capabilities; establishing standards; confirming manufacturing processes.

• Provides upfront input into prototype and production designs, including machining time, labor estimates, tooling cost, and material selection.

• Support development of work instructions, machining standards, and best practices.

• Serve as a technical resource for manufacturability and machining feasibility questions.

• Train and support manufacturing and assembly personnel as needed.

• Contributes to continuous improvement initiatives and cross-functional problem solving.

Minimum Qualifications – Two Equivalent Pathways

Path A: Engineering Degree + Experience

• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, or related field

• Minimum 8–10 years of experience in manufacturing engineering, DFM/DFA, or related roles

• Demonstrated success applying DFM principles in a production environment

Path B: CNC Machining Experience (No Degree Required)

• Minimum 10–15+ years of progressive CNC machining experience in a production and/or prototype environment

(20+ years strongly preferred)

• Proven track record as a senior-level CNC machinist with deep understanding of:

• CNC and manual milling and lathe

• Complex setups, fixturing, and work holding

• Tolerance stack-ups and process capability

• Tooling selection and machining strategy

• Demonstrated experience contributing to design-for-manufacture decisions, including recommending design changes to improve machinability, cost, and quality

• Ability to function as a technical authority across machining and manufacturing teams

Note: Candidates qualifying through either pathway are considered equal for this role. This position values applied manufacturing expertise on the same level as formal engineering education.

Job Requirements

• Strong understanding of DFM/DFA principles

• Solid knowledge of sheet metal design, including self-fixturing concepts

• Ability to interpret and influence CAD models and engineering drawings

(Autodesk Inventor experience preferred; CAD proficiency required regardless of pathway)

• Working knowledge of CNC programming strategies (e.g., Mastercam or similar CAM systems)

• Strong mechanical aptitude with understanding of:

• Pneumatic, hydraulic, and servo systems

• Machine controls and automation

• Familiarity with statistical test procedures and corrective action techniques

• Strong problem-solving and analytical skills

• Effective written and verbal communication skills, especially between engineering and shop-floor teams

• Ability to manage multiple priorities and drive work to completion

• Self-motivated, adaptable, and comfortable leading change

Working Conditions

The employee typically performs duties in a normal office environment. There may be some work in a manufacturing environment and exposure to the elements of our factory. Additionally, there may be some work performed in the field with exposure to construction sites or active customer facilities. It is the policy of Powell Industries to promote safe working conditions for ALL employees, to make available where necessary special equipment to protect employees against specific hazards, to reduce accidents through prevention programs, and to establish rules that are designed for the safety of all. It is the responsibility of each employee to adhere to this policy, as well as to observe all safety practices and exercise every precaution for the safety of accidents. This position is expected to travel 5-10% of the tie and must be able to travel with short notice and/or for extended periods.

Physical Requirements

The physical demands described here are representative of those that must be met by an employee to perform the essential functions of this job successfully. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

• Regularly required to use hands to touch, hold, handle, or feel

• Frequently required to stand, sit, walk and reach with hands and arms; stoop kneel, crouch, or crawl; and talk or hear

• Must occasionally lift and/or move up to 65 pounds

• Maintaining body equilibrium and agility to prevent falling when walking, standing, crouching, ascending, or descending stairs

#LI-CAB

In our 75+ year history, Powell has always known that our employees are at the heart of our success. Without question, we have the most talented people in all parts of our organization. As a manufacturer, we recruit and hire experienced and knowledgeable applicants to ensure our product is engineered, fabricated, and assembled to customer specifications!

Powell’s culture has and will always be founded in our "can do" attitude. If we can imagine it, we can do it. Become a part of our story and let us help you write yours. Hard work pays off in all our teams, with opportunity for advancement and promotion without sacrificing work-life balance. Successful candidates must have a legal authorization to work in the United States on a full-time basis, with only those candidates selected for interview contacted.

Powell offers comprehensive health insurance for you and your family, 401k savings, annual bonus potential, generous paid time off, professional development opportunities, company-sponsored wellness programs, and a collaborative work environment.

EOE Protected Veterans/Disability

If you need an accommodation in the hiring process, you may contact 713.378.2685. Application status inquiries will not be accepted in this manner.