Senior DFx Engineer Security Clearance

Position: Senior DFx Engineer with Security Clearance
About us One team. Global challenges. Infinite opportunities. At Viasat, we're on a mission to deliver connections with the capacity to change the world. For more than 35 years, Viasat has helped shape how consumers, businesses, governments and militaries around the globe communicate. We're looking for people who think big, act fearlessly, and create an inclusive environment that drives positive impact to join our team.

What you'll do We are looking for a Senior DFx Engineer to join our Operations teams! In this role, you will use your advanced knowledge of Surface Mount Technology (SMT) processes and DFx principles to improve product readiness for production across all development phases. You will play a critical role in ensuring robust PWA designs and SMT assembly workflows for sophisticated PWAs, driving higher yields, lower costs, and improved reliability.

The day-to-day
* Participate in design reviews to ensure component placement, pad design, and stencil aperture meet manufacturability standards.

* Provide feedback to design engineers on layout and thermal considerations.

* Run small-scale experiments (DoEs) to validate SMT parameters like solder paste type, stencil thickness, and reflow profiles.

* Perform CpK analysis and Gage R R studies to confirm process capability and measurement accuracy.

* Work with the EMS and PE to establish, monitor, and optimize SMT assembly steps: screen printing, SPI, pick-and-place, reflow profiling, AOI, AXI, and selective soldering.

* Review production data and address any anomalies in SMT workflows or design related issues that affect yield.

* Communicate with contract manufacturers to align on SMT standard methodologies and resolve process issues.

* Support NPI builds and solve assembly challenges with design and manufacturing teams.

* Drive cost-reduction and yield-improvement initiatives at supplier sites.

* Serve as "the" technical resource to interdisciplinary teams, councils, and management.

* Provide technical leadership and mentoring to junior engineers.

* Communicate progress and risks to stakeholders effectively.

* Investigate defects such as tomb stoning, solder voids, or insufficient wetting using SEM, X-ray, and optical microscopy.

* Document findings and implement corrective actions.

* Maintain DFx checklists, processes, and best-practice guidelines.

* Engage with quality on PFMEA/DFMEA engagements for producibility enhancement opportunities on future designs.

* Find opportunities for automation and inspection enhancements.

* Monitor SMT yield, process capability, and improvement initiatives.

* Maintain clear records of validation results and corrective actions.

* Provide build readiness updates using PRS, Producibility Reports, and updates at critical design reviews. What you'll need
* BS degree in Engineering or equivalent experience.

* 10+ years of proven experience in high-mix, high-density SMT assembly environments, including fine-pitch and BGA components.

* Proven teammate with strong networking and communication abilities, capable of influencing decisions and working seamlessly across diverse technical teams.

* Ability to prioritize tasks, maintain attention to detail, and manage time effectively to handle multiple responsibilities concurrently.

* Strong understanding of IPC-A-610, IPC-7351, J-STD-001, and SMT-specific inspection criteria.

* Extensive experience applying design-for-manufacturability principles to PWA architecture and assembly workflows, reducing cost and improving reliability.

* Skilled in reflow profiling, stencil design optimization, solder paste selection, and thermal management for complex assemblies.

* Familiarity with SMT process simulation and analysis tools (Valor, Minitab) and inspection systems (AOI, AXI).

* Ability to identify root causes of SMT defects and implement corrective actions quickly. Experienced in using PFMEA and DFMEA evaluations to drive producibility, quality, cost, and reliability in product development.

* U.S. Citizenship required.

* Ability to travel (up to 20%) for on-site process validation and technical support. What will help you on the job
* Skilled in driving process evaluations and validations with…