Senior NPI Manufacturing Engineer

The Sr. NPI Manufacturing Engineer will lead the development, validation, and industrialization of manufacturing processes to support the successful introduction of new UAV systems into production within the aerospace and defense sector. This role is responsible for owning New Product Introduction (NPI) from early design phases through production ramp, ensuring designs are optimized for manufacturability, scalability, quality, and cost.

This individual will serve as a key cross-functional leader, partnering with Engineering, Quality, Supply Chain, and Operations to drive Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Test (DFT) initiatives. The ideal candidate brings deep experience in aerospace manufacturing and thrives in fast-paced environments, enabling seamless transitions from prototype builds (EVT/DVT/PVT) through LRIP and full-rate production.

• Lead NPI efforts from concept through production ramp, including EVT, DVT, PVT, and LRIP phases.
• Own manufacturing readiness, ensuring processes, tooling, documentation, and training are in place for successful product launches.
• Drive DFM/DFA/DFT reviews with design engineering to ensure scalable, cost-effective, and high-quality product designs.
• Develop, validate, and implement manufacturing and test processes for new UAV systems.
• Design, procure, and validate jigs, fixtures, tooling, and automation solutions to support production efficiency and repeatability.
• Serve as the primary manufacturing point of contact for new product programs, ensuring alignment across cross-functional teams.
• Support prototype builds and production ramp by troubleshooting issues, reducing variability, and improving yield and throughput.
• Lead root cause analysis and corrective actions for design and process-related issues during NPI phases.
• Develop and maintain manufacturing documentation including work instructions, SOPs, PFMEAs, control plans, and build plans.
• Drive implementation of Lean Manufacturing principles such as 5S, value stream mapping, standard work, and Kaizen events.
• Perform time studies, capacity planning, and cost analysis to support production scalability and resource planning.
• Integrate automation, advanced manufacturing technologies, and Industry 4.0 solutions into new product lines.
• Ensure compliance with AS9100, ISO, ITAR, and other aerospace/defense regulatory requirements.
• Mentor junior engineers and provide technical leadership across NPI initiatives.
• Perform other duties as assigned

• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or related field.
• 7–12+ years of experience in aerospace manufacturing engineering, with a strong focus on New Product Introduction (NPI), preferably in UAV, aerospace, defense, or high-precision manufacturing environments.
• Deep expertise in NPI processes including EVT, DVT, PVT, and production ramp.
• Strong knowledge of manufacturing methods (composites, machining, assembly, automation).
• Advanced proficiency in DFM/DFA/DFT methodologies.
• Experience with CAD and manufacturing systems (e.g., SolidWorks, AutoCAD, ERP/MRP).
• Strong understanding of process validation, PFMEA, control plans, and SPC.
• Excellent problem-solving, data analysis, and root cause investigation skills.
• Ability to interpret complex engineering drawings, specifications, and aerospace standards.
• Strong cross-functional leadership and project management capability.
• Ability to operate effectively in fast-paced, high-growth environments.

• Lean Six Sigma Green Belt or Black Belt, preferred
• PMP (Project Management Professional), preferred
• Experience leading full product lifecycle industrialization in aerospace or defense.
• Strong background in automation and Industry 4.0 implementation.
• Proven ability to drive successful product launches from prototype to production.
• Familiarity with AS9100, IPC standards, ISO9001, MIL-STD, and FAA guidance.
• Experience mentoring and developing engineering teams.

• Must be able to work in a manufacturing environment with exposure to machinery, noise, and airborne particles
• May be required to stand, walk, and lift up to 25 pounds regularly

Background Check

This position will require successfully completing a post-offer background check. Qualified candidates with a criminal history will be considered and are not automatically disqualified, consistent with federal and state law.

EEO and ITAR/EAR Work Authorization Disclosure

Red Cat Holdings provides equal employment opportunities (EEO) to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. This position requires direct or indirect access to hardware, software, technology or technical data controlled under the International Traffic in Arms Regulations (ITAR) and the Export Administration Regulations (EAR). Successful candidates for positions subject to ITAR/EAR restrictions must provide proof of U.S. Citizenship or Permanent Residence and must not require sponsorship for export-restricted work authorization.

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