Automation Engineer, Controls

Job description

About Mach Industries Founded in 2023, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 350 employees, we operate with startup agility and ambition. Our vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security. The Role Mach Industries is seeking an Automation Engineer, Controls to develop, integrate, and commission automated manufacturing equipment across our factories. You will design and program controls systems using Mach's standardized Beckhoff TwinCAT platform, working directly with manufacturing engineers, automation engineers, equipment OEMs, and systems integrators to take equipment from concept through production. This is a highly hands-on engineering role. You will develop PLC software, integrate sensors, motion systems, robotics, vision, and safety devices, commission equipment on the factory floor, and troubleshoot automation systems during production ramp. Key Responsibilities • Design, program, integrate, and commission controls systems for automated manufacturing equipment. • Develop PLC software using Beckhoff TwinCAT and Mach's standardized controls architecture and software libraries. • Configure Beckhoff IPCs, EtherCAT I/O, servo drives, instrumentation, sensors, and industrial communication networks. • Develop machine sequences, state machines, interlocks, alarms, fault handling, diagnostics, and recovery logic. • Integrate PLC-controlled equipment with industrial robots, machine vision, motion systems, test equipment, and process instrumentation. • Implement machine-safety systems including safety PLC logic, interlocks, guarding, emergency stops, and safe motion. • Develop HMIs and operator interfaces for equipment operation, diagnostics, maintenance, and fault recovery. • Support electrical design, controls architecture, I/O definition, device selection, and equipment documentation. • Develop and execute controls test plans and equipment acceptance criteria. • Work directly with equipment OEMs and systems integrators to review and debug controls systems. • Support FAT, SAT, installation, commissioning, and production launch. • Troubleshoot electrical, PLC, motion, robotics, vision, networking, and safety issues directly on manufacturing equipment. • Optimize machine sequences, cycle time, fault recovery, reliability, and OEE during production ramp. • Maintain controls documentation, software version control, backups, and equipment configuration. • Support manufacturing equipment through achievement of Run at Rate and transition to production operations. Required Qualifications • Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Mechanical Engineering, Computer Engineering, or a related discipline. • 2+ years of experience developing industrial automation, controls, or automated manufacturing equipment. • Hands-on PLC programming experience. • Experience integrating sensors, actuators, distributed I/O, instrumentation, or motion-control systems. • Understanding of industrial electrical and controls systems including 24 VDC I/O, relays, contactors, drives, motors, and industrial networks. • Experience developing machine sequences, interlocks, alarms, fault handling, and recovery logic. • Experience commissioning or troubleshooting automated equipment. • Ability to read electrical schematics and troubleshoot electrical and controls systems directly on manufacturing equipment. • Strong hands-on problem-solving skills and willingness to support equipment installation, commissioning, and production ramp. Preferred Qualifications • Experience with Beckhoff TwinCAT 3 and IEC 61131-3 Structured Text. • Experience with Beckhoff IPCs, EtherCAT, TwinSAFE, distributed I/O, and servo motion. • Experience with industrial robotics such as FANUC, ABB, KUKA, Yaskawa, Universal Robots, or similar. • Experience integrating machine vision, automated test systems, instrumentation, or advanced motion systems. • Experience developing HMIs or industrial operator interfaces. • Familiarity with machine-safety concepts including safety PLCs, guarding, interlocks, emergency stops, and safe motion. • Familiarity with OPC UA, MQTT, or other machine-to-software communication methods. • Experience with Git or other software version-control systems. • Experience working with systems integrators or equipment OEMs through FAT, SAT, commissioning, and production launch. • Familiarity with machine and electrical safety standards including ISO 13849, NFPA 79, and NFPA 70. • Experience in aerospace, defense, automotive, semiconductor, battery, chemical processing, or other advanced manufacturing environments. Additional Requirements • Available to work extended hours and weekends as needed ITAR Requirements To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here. Engineer $115,000—$150,000 USD Senior Engineer $150,000—$195,000 USD At Mach, we believe that compensation is more than just a paycheck. It's a comprehensive package designed to reward the time, skills, and expertise you bring to our team. We are committed to offering competitive compensation that is equitable, transparent, and aligned with market trends. Key Elements of Our Compensation Philosophy: • Co