R&D Manufacturing Director

Our client is seeking a hands-on R&D Manufacturing Director to lead the manufacturing of first‑of‑kind prototypes, demonstration units, and low‑rate initial production hardware for advanced laser and electro‑optical systems used in aerospace and space applications. This includes engineering development units (EDUs), flight units, and early production builds.

This is a highly technical, execution-focused leadership role. The Director will be deeply involved in day‑to‑day manufacturing operations while also driving long‑term capability improvements, updating core processes, implementing a Manufacturing Execution System (MES), and helping scale production capacity. The role serves as the operational bridge between engineering, configuration management, quality, supply chain, planning, and the build teams. This position is onsite in Herndon, VA.

Key Responsibilities:

Shop & Operations Leadership

• Oversee production shops including optical assembly, electronics assembly, parts cleaning, and machine shop operations
• Identify constraints and drive continuous improvement across the production floor

Production Planning & Execution

• Develop work instructions with design engineers to ensure efficient, predictable assembly and test
• Ensure build packages, travelers, drawings, and procedures are complete and build‑ready
• Validate build schedules and resource plans for feasibility
• Serve as the primary escalation point for manufacturing execution issues

Manufacturing Engineering & Process Improvement

• Provide Design for Manufacturing (DFM) feedback and define build strategy and flow
• Standardize and improve manufacturing processes for repeatability, traceability, and throughput
• Select, implement, and operationalize a Manufacturing Execution System (MES)
• Resolve nonconformances using structured root‑cause analysis

AI&T Process Ownership

• Own the process from released design through assembly and integration
• Act as the integration point across engineering, configuration management, quality, safety & mission assurance, supply chain, planning, and build teams

Facilities & Team Leadership

• Lead and develop the manufacturing engineering team while remaining hands‑on
• Partner with leadership to plan facility improvements aligned with future program needs

Requirements

Minimum Requirements

• 10–15 years of experience in manufacturing engineering or production leadership
• Background in optical, laser, electro‑optical, aerospace, or space‑qualified hardware
• Experience transitioning designs through prototype, development, and early production
• Direct experience with Assembly, Integration & Test (AI&T) in controlled build environments
• Strong understanding of configuration control, build documentation, and traceability
• Experience with ERP systems (Deltek Costpoint preferred)
• Experience in ISO‑9001 or AS9100 manufacturing environments
• Bachelor’s degree in a technical discipline (engineering preferred)
• Proven hands‑on leadership style

Benefits

Our client is a recognized leader in advanced laser, lidar, and laser‑communication technologies, delivering high‑performance electro‑optical solutions for defense, space, and aerospace missions. The organization is known for its innovation, technical excellence, and customer‑focused culture, supported by a collaborative and flexible work environment.

They foster a progressive learning culture that values curiosity, encourages professional challenge, and supports long‑term growth. Employees enjoy a competitive compensation package, strong benefits, and the opportunity to contribute to cutting‑edge programs with real mission impact.