Principal Automation Engineer, Controls

The Role

Mach Industries is seeking a Principal Automation Engineer, Controls to own the architecture, development, and deployment of our factory controls platform.

You will establish Beckhoff TwinCAT as Mach's standardized controls platform, personally develop automation equipment for pilot production lines, and scale those architectures through external systems integrators executing $20M+ capital equipment programs.

This is a hands-on technical leadership role. You will be expected to move between defining controls architecture and standards, writing and debugging production code, reviewing integrator designs, commissioning equipment on the factory floor, and solving problems during production ramp.

Your ownership extends from initial controls architecture through FAT, installation, commissioning, and Run at Rate.

Key Responsibilities

• Own Mach's factory controls architecture and technical roadmap, standardized around Beckhoff TwinCAT.
• Define standards for PLC software, Beckhoff IPCs, EtherCAT I/O, motion control, industrial networks, machine safety, diagnostics, and factory interfaces.
• Develop reusable TwinCAT software libraries, machine state models, fault handling, recovery strategies, and programming standards.
• Own controls and functional-safety architecture, including safety PLCs, safe motion, interlocks, guarding, emergency stops, and safety validation.
• Personally design, program, integrate, and commission automation equipment for pilot manufacturing lines.
• Translate successful pilot architectures into scalable equipment standards and specifications for production systems.
• Develop controls requirements, Statements of Work, design standards, and acceptance criteria for externally integrated equipment.
• Serve as the controls technical lead for systems integrators executing $20M+ automation programs.
• Lead technical design reviews across electrical systems, PLC software, robotics, motion, networking, machine safety, and factory interfaces.
• Lead controls execution through FAT, SAT, installation, commissioning, and production launch.
• Troubleshoot complex interactions between PLCs, robotics, motion systems, machine vision, instrumentation, safety systems, and factory software.
• Optimize machine sequences, cycle time, fault recovery, reliability, and OEE during production ramp.
• Maintain technical ownership until manufacturing systems achieve defined Run at Rate and production-readiness milestones.
• Mentor automation engineers and establish controls engineering best practices across Mach.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Mechanical Engineering, Computer Engineering, or a related discipline.
• 8+ years of experience developing industrial automation, controls, or complex electromechanical systems.
• Strong PLC programming experience and the ability to personally develop and debug production controls software.
• Demonstrated ownership of controls architecture for complex automated equipment or manufacturing systems.
• Experience taking automated equipment from design through integration, commissioning, and production.
• Experience designing or implementing machine-safety and functional-safety systems.
• Experience working directly with systems integrators, equipment OEMs, or automation suppliers.
• Strong understanding of industrial networks, distributed I/O, motion control, instrumentation, robotics, and machine integration.
• Demonstrated ability to independently troubleshoot complex equipment in a production environment.

Preferred Qualifications

• Experience with Beckhoff TwinCAT 3, particularly IEC 61131-3 Structured Text.
• Experience with Beckhoff IPCs, EtherCAT, TwinSAFE, distributed I/O, and servo motion.
• Experience developing reusable PLC software libraries or standardized controls architectures deployed across multiple machines.
• Experience serving as a controls technical lead for large, multi-machine automation or capital equipment programs.
• Experience with industrial robotics, machine vision, automated test systems, and advanced motion control.
• Experience integrating controls systems with SCADA, MES, historians, traceability, or factory data infrastructure.
• Familiarity with OPC UA, MQTT, or other machine-to-software communication architectures.
• Working knowledge of functional and machine-safety standards including ISO 13849, IEC 62061, IEC 61508, NFPA 79, and NFPA 70.
• Experience in aerospace, defense, automotive, semiconductor, battery, chemical processing, or similarly demanding manufacturing environments.

Additional Requirements

• Available to work extended hours and weekends as needed

ITAR Requirements

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.

Pay and benefits

At Mach, we believe that compensation is more than just a paycheck. It's a comprehensive package designed to reward the time, skills, and expertise you bring to our team. We are committed to offering competitive compensation that is equitable, transparent, and aligned with market trends.

Key Elements of Our Compensation Philosophy

• Competitive Salaries: We continuously research market rates to ensure our salaries are competitive with those in our industry and geographic location.
• Performance-Based Incentives: Our bonus structure is tied to both individual and company performance, creating a win-win scenario that motivates our team members to excel.
• Equity Participation: We offer stock options or equity to employees, ensuring that you share in the success and growth of the company.
• Benefit Packages: Our benefits include healthcare, dental and vision plans, retirement savings, and paid time off, because we understand that your well-being extends beyond the office.
• Professional Development: We allocate funds for continuing education, training, and career growth.
• Transparency: We are committed to openness about our compensation tiers and how decisions are made, ensuring trust and mutual respect.

By joining Mach, you're not just accepting a job-you're becoming a key part of a team that values your contributions and invests in your growth. Together, we aim to create a rewarding environment that sets the stage for long-term success.

Data Privacy

Disclosures

This position may require access to information protected under U.S. export control laws and regulations, including the Export Administration Regulations (EAR) and the International Traffic in Arms Regulations (ITAR). Please note that any offer for employment may be conditioned on authorization to receive software or technology controlled under these U.S. export control laws and regulations without sponsorship for an export license.

The salary range for this role is an estimate based on a wide range of compensation factors, inclusive of base salary only. Actual salary offers may vary based on (but not limited to) work experience, education and training, critical skills, and business considerations. Highly competitive equity grants are included in most offers and are considered part of Mach's total compensation package. Mach offers benefits such as health insurance, retirement plans, and opportunities for professional development.