Staff Hardware Engineer, DFx (Manufacturing, Test & Tooling)

General Motors (GM)

Confirmed live today High trust
Hybrid

Quick summary

Work type
Hybrid
Location
Warren, MISunnyvale, CA
Salary
$159,400–$245,000 / yr
Employment
Full-time
Posted
133 days ago
Freshness
Confirmed live today

Market check

Salary context

Competitive pay

How this pay compares to similar roles

Similar $187k
This role $202k
$139k $256k
below market most similar roles pay here above market

This role pays more than 64% of similar roles. Most pay $160,000–$213,375 — the blue band above. At the midpoint, this role pays about $202k versus about $187k for comparable roles.

Based on 240 similar postings.

Employer

About General Motors (GM)

General Motors (GM) is a leading American multinational automotive corporation founded in 1908 and headquartered in Detroit, Michigan.

General Motors (GM) currently has 196 open roles on FindRole.

Listed pay typically runs $159,200–$245,000 across 54 roles with salary data.

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At a glance

TL;DR · Staff Hardware Engineer, DFx (Manufacturing, Test & Tooling)

The Staff Hardware Engineer – DFx (Manufacturing, Test & Tooling) joins a high-energy team serving as the critical link between internal design teams and contract manufacturers for next-generation ECUs. This role focuses on circuit board design, population, test, and assembly for electrical controllers supporting Software Defined Vehicle architecture. You will lead DFx strategy, establishing processes for in-house designs by embedding best practices for manufacturing, assembly, and testing. Key responsibilities include selecting test point locations, performing GD&T and tolerance stacks, and creating 3D and 2D CAD models. You will utilize expertise in Solder Paste/Stencil processes, SPI, AOI, and Reflow profiles to manage the transition from bare boards to fully populated PCBs. Required skills include proficiency in 3D CAD modeling, schematic designs, test software development, and tolerance analysis.

What you'll do

  • Establish and drive DFx processes for in-house designs to ensure alignment between design and manufacturing.
  • Lead DFx strategy and execution for electrical controllers supporting the Software Defined Vehicle architecture.
  • Select test point locations, in-circuit board coverage, functional test requirements, and programming requirements.
  • Perform design calculations, GD&T, and tolerance stacks required for tooling and test fixtures.
  • Create 3D and 2D CAD models and lead CAD reviews with internal and external stakeholders.
  • Develop analysis and test plans for new designs and perform proof of concept testing.
  • Lead prototyping and analyze test data to adjust manufacturing processes, materials, and tooling designs.
  • Communicate contract manufacturing progress and risks to internal stakeholders and customers.

What we're looking for

  • BS in Electrical or Mechanical Engineering or equivalent engineering degree.
  • 7+ years in-plant electronic control module manufacturing experience leading a cross-functional team of Design/Manufacturing engineers.
  • Proficiency in 3D CAD modeling, 2D drawings, schematic designs, test SW development, tolerance analysis, design for manufacturability, and assembly.
  • Strong analytical skills and engineering fundamentals in manufacturing, testing, and tooling of automotive electronic modules.
  • Hands-on experience engaging with electronics manufacturers.
  • Exceptional collaboration and teamwork skills with a demonstrated ability for working across functional and organizational boundaries.
  • Master’s degree/PhD in Electrical or Mechanical Engineering (preferred).
  • Experience establishing a DFx organization within an automotive OEM (preferred).

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