Senior DFx Engineering Program Manager Scottsdale, Arizona, Scottsdale, Arizona

Location:

Scottsdale, Arizona, United States

We have an aggressive schedule for development and release of the next generation of de‑escalation devices. The NPI group is driving changes to ensure that new products can be built at scale with high yield and low cost, and we need highly skilled, motivated, technical engineers to set expectations and drive results from various internal and external partners from design to mass production.

You’ll work with a wide range of functional teams and always have opportunities to make a meaningful impact across the organization.

Location:

Onsite in Scottsdale/Phoenix, AZ office

Reports to:

Sr. Director, NPI Engineering

As a Sr DFx Engineering Program Manager, you will play a key technical role in the development and launch of new products, supporting the Engineering Program Manager and cross-functional teams to ensure designs are ready for scale. You’ll be deeply involved in prototype builds, factory readiness, and the development of automation and test systems—bringing a strong foundation in manufacturing engineering, DFM/DFA, and hands‑on technical execution.
This role is ideal for an engineer who thrives at the intersection of product design, manufacturing, and automation—and enjoys getting into the details to make products scalable, efficient, and robust.

• Drive comprehensive DFx reviews (DFM, DFA, DFT, DFS, DFR, DFQ) throughout SP, EVT, and DVT to identify design risks, cost drivers, yield limitations, and reliability concerns prior to release.
• Partner with design, reliability, test, and manufacturing teams to translate DFx findings into concrete design changes, manufacturing requirements, and validation plans that enable high-volume, high-yield production.
• Support the Engineering Program Manager in planning and executing builds through Axon’s Product Lifecycle (APL) including System Prototype (SP), Engineering Validation (EVT), Design Validation (DVT), and Production Validation (PVT).
• Ensure new product designs are scalable and manufacturable by driving DFM and DFA activities with design engineering teams.
• Lead the development and coordination of assembly/test processes, including process flow, fixture design, automation systems, and manufacturing equipment.
• Perform tolerance stack‑up analysis on assembly jigs and fixtures to ensure product conformance.
• Provide hands‑on support in the design of tools, jigs, and factory layouts using Solid Works, Creo or equivalent CAD tools.
• Design and execute Design of Experiments (DOE) to optimize manufacturing processes and validate critical parameters.
• Collaborate with Axon Manufacturing, contract manufacturers (CMs), joint development manufacturers (JDMs) and equipment suppliers to align on process capabilities, equipment requirements, and build readiness.
• Act as the subject matter expert (SME) in Automation and scalability of diverse mechanical and electro‑mechanical devices.
• Manufacturing and assembly processes including leak testing, fixture design, B2B connections, adhesives, welding, etc.
• Quality assurance including DOEs, measurement system analysis (MSA), and automated inspections.
• Direct or guide process decisions throughout SP and EVT phases.
• Drive root cause analysis and corrective actions during development builds and early production phases.
• Track factory readiness across engineering, test, automation, quality, and supply chain functions.
• Conduct risk assessments and help implement mitigation strategies for production issues.
• Analyze production data and test results to identify trends, variances, and opportunities for improvement.
• Assist with preparing technical reports, build summaries, and presentations for internal teams and leadership.
• Develop Process Flow Diagrams, PFMEAs, Hazard Analysis, and other critical documents.

• B.S. in Mechanical, Electrical, Manufacturing, or related engineering field plus 8 years of experience in NPI, manufacturing, or automation engineering (preferably in electronics or consumer hardware). Alternatively, M.S. in equivalent field plus 6 years of related experience.
• Track record of successful product launches in a…