Principal 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 a Principal Automation Engineer, Controls to own the architecture, development, and deployment of our factory controls platform. You will establish Beckhoff TwinCAT as Mach's standardized controls platform, personally develop automation equipment for pilot production lines, and scale those architectures through external systems integrators executing $20M+ capital equipment programs. This is a hands-on technical leadership role. You will be expected to move between defining controls architecture and standards, writing and debugging production code, reviewing integrator designs, commissioning equipment on the factory floor, and solving problems during production ramp. Your ownership extends from initial controls architecture through FAT, installation, commissioning, and Run at Rate. Key Responsibilities • Own Mach's factory controls architecture and technical roadmap, standardized around Beckhoff TwinCAT. • Define standards for PLC software, Beckhoff IPCs, EtherCAT I/O, motion control, industrial networks, machine safety, diagnostics, and factory interfaces. • Develop reusable TwinCAT software libraries, machine state models, fault handling, recovery strategies, and programming standards. • Own controls and functional-safety architecture, including safety PLCs, safe motion, interlocks, guarding, emergency stops, and safety validation. • Personally design, program, integrate, and commission automation equipment for pilot manufacturing lines. • Translate successful pilot architectures into scalable equipment standards and specifications for production systems. • Develop controls requirements, Statements of Work, design standards, and acceptance criteria for externally integrated equipment. • Serve as the controls technical lead for systems integrators executing $20M+ automation programs. • Lead technical design reviews across electrical systems, PLC software, robotics, motion, networking, machine safety, and factory interfaces. • Lead controls execution through FAT, SAT, installation, commissioning, and production launch. • Troubleshoot complex interactions between PLCs, robotics, motion systems, machine vision, instrumentation, safety systems, and factory software. • Optimize machine sequences, cycle time, fault recovery, reliability, and OEE during production ramp. • Maintain technical ownership until manufacturing systems achieve defined Run at Rate and production-readiness milestones. • Mentor automation engineers and establish controls engineering best practices across Mach. Required Qualifications • Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Mechanical Engineering, Computer Engineering, or a related discipline. • 8+ years of experience developing industrial automation, controls, or complex electromechanical systems. • Strong PLC programming experience and the ability to personally develop and debug production controls software. • Demonstrated ownership of controls architecture for complex automated equipment or manufacturing systems. • Experience taking automated equipment from design through integration, commissioning, and production. • Experience designing or implementing machine-safety and functional-safety systems. • Experience working directly with systems integrators, equipment OEMs, or automation suppliers. • Strong understanding of industrial networks, distributed I/O, motion control, instrumentation, robotics, and machine integration. • Demonstrated ability to independently troubleshoot complex equipment in a production environment. Preferred Qualifications • Experience with Beckhoff TwinCAT 3, particularly IEC 61131-3 Structured Text. • Experience with Beckhoff IPCs, EtherCAT, TwinSAFE, distributed I/O, and servo motion. • Experience developing reusable PLC software libraries or standardized controls architectures deployed across multiple machines. • Experience serving as a controls technical lead for large, multi-machine automation or capital equipment programs. • Experience with industrial robotics, machine vision, automated test systems, and advanced motion control. • Experience integrating controls systems with SCADA, MES, historians, traceability, or factory data infrastructure. • Familiarity with OPC UA, MQTT, or other machine-to-software communication architectures. • Working knowledge of functional and machine-safety standards including ISO 13849, IEC 62061, IEC 61508, NFPA 79, and NFPA 70. • Experience in aerospace, defense, automotive, semiconductor, battery, chemical processing, or similarly demanding 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. Principal Engineer $195,000—$225,000 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