Interconnect Systems Manufacturing Engineer

Job DescriptionJob Description

Job Description

Title: (Sr.) Electronics Manufacturing Engineer – Interconnect Systems & PCB Assembly
Location: Palo Alto, CA
Employment Type: Full-Time, Onsite (Exempt)

Compensation: $150k+

Company & Position Summary:

At CalTek Staffing is seeking a driven Senior Electronics Manufacturing Engineer to join an electric aircraft OEM developing a next-gen platform for consumer and specialized applications as they prepare to expand their critically integrated manufacturing operations.

This engineer will play a central role in building out the production framework for complex wire harness assemblies and printed circuit board assemblies (PCBAs). From initial prototyping through to scaled manufacturing, this position requires collaboration with engineering design teams to ensure seamless product transitions into the production environment.

You’ll take charge of production workflows related to harnesses and PCB assemblies, partnering with internal assembly teams and external production partners. Your focus will be on driving process excellence, optimizing factory-floor operations, and supporting continuous improvement initiatives. Additionally, you’ll lead electrical integration efforts for the aircraft—including installation, routing, and connection of electronic systems—ensuring consistent quality and reliability throughout.

We’re looking for an experienced engineer with deep expertise in aerospace or perhaps even automotive wiring systems and electronic hardware manufacturing—someone who thrives in fast-paced, hands-on environments and is passionate about delivering precision-built hardware.

Key Areas of Focus:

Cable & Wire Harness Production:

o   Develop robust manufacturing methods for cable assemblies in line with aerospace standards (IPC/WHMA-A-620).

o   Collaborate with designers to ensure product manufacturability.

o   Draft detailed instructions, tooling guides, and build documentation for harness fabrication.

o   Resolve production bottlenecks and implement corrective actions to meet delivery goals.

o   Manage harness suppliers to maintain timelines and ensure adherence to safety and quality benchmarks.

Electronics Manufacturing Support:

o   Provide technical assistance for PCB assembly, battery builds, and other electronic hardware.

o   Partner with vendors to address technical hurdles and bolster component reliability.

o   Support design-for-manufacturing (DFM) and design-for-testability (DFT) improvements.

o   Process Development & Optimization:

o   Introduce Lean Manufacturing practices to improve throughput, reduce waste, and increase efficiency.

o   Conduct time studies and root cause analyses to drive process enhancements.

o   Evaluate and implement new manufacturing technologies and automation where applicable.

Compliance & Documentation:

o   Ensure all operations follow strict aerospace regulations and internal quality requirements.

o   Keep detailed, audit-ready records such as process documentation, engineering changes, and quality reports.

o   Prepare for quality audits tied to standards like AS9100 and ISO 9001.

o   Cross-Functional Teamwork:

o   Collaborate with engineering, quality, and supply chain groups to smooth the transition from development to production.

o   Support design for manufacturability (DFMA) efforts for electronic assemblies and harnesses.

o   Mentor production technicians and engineers in harness assembly and electronics best practices.

Required Skills & Experience:

• Bachelor’s degree in Engineering (Mechanical, Electrical, Aerospace, or related field).
•  Several years of hands-on experience in harness and electronics assembly within a manufacturing setting.
• Strong working knowledge of aerospace wiring materials, connectors, soldering methods, PCBs, conformal coatings, and related components.
• Experience supporting projects through full product life cycles—from prototype through production.
• Proven ability to handle competing priorities in a dynamic work environment.
• Familiarity with CAD and harness design software (CATIA, 3DX Systems, or similar).
• Knowledge of standards such as IPC-A-610, IPC/WHMA-A-620, J-STD-001, SAE AS50881, and AS9100.
•  Proficient with process control tools like PFMEA, SPC, and Control Plans.

Extras:

• Master’s degree in an applicable engineering discipline.
• IPC-620 certification.
• Experience working on emerging aerospace technologies, including eVTOL systems.
• Familiarity with Part 103 regulatory requirements.
• Basic programming skills for automation/testing equipment are a plus.

Company DescriptionCalTek is a manufacturing, technical, engineering and IT consulting firm that has expanded its business operations from its headquarters in San Diego, throughout all of California and into Arizona, Colorado, Florida, Georgia, Texas and Washington. CalTek has staffed positions with global companies such as Siemens, Parsons, and Illumina but also works with startups with 10+ employees.Company DescriptionCalTek is a manufacturing, technical, engineering and IT consulting firm that has expanded its business operations from its headquarters in San Diego, throughout all of California and into Arizona, Colorado, Florida, Georgia, Texas and Washington. CalTek has staffed positions with global companies such as Siemens, Parsons, and Illumina but also works with startups with 10+ employees.