Senior Principal Design Manager

📍 Job Overview

Job Title: Senior Principal Design Manager

Company: BYRNA TECHNOLOGIES INC

Location: Andover, MA

Job Type: Full-time

Category: Engineering Management / Operations

Date Posted: May 12, 2026

Experience Level: 15+ Years

Remote Status: On-site

🚀 Role Summary

• This senior-level role combines strategic engineering leadership with hands-on technical execution, focusing on establishing and elevating design standards and engineering culture.

• You will act as the primary authority for Design for Manufacturability (DFM) and Design for Excellence (DFx) principles within the R&D organization, ensuring consistency and quality across all products.

• The position requires a "player-coach" approach, balancing the ownership of high-priority product development cycles with the mentorship and development of mid- and junior-level engineers.

• Success in this role hinges on driving end-to-end product development, building a robust engineering culture, and ensuring products are designed for manufacturability, quality, and long-term reliability.

📝 Enhancement Note: While the title is "Design Manager," the core responsibilities and qualifications strongly indicate a senior individual contributor role with significant leadership and mentorship duties, rather than direct people management of a large team. The "player-coach" description and the ~40% coaching / 60% hands-on split reinforce this. The role is positioned as the "senior principal engineering authority."

📈 Primary Responsibilities

• Serve as the DFx and design standards authority for the R&D organization, defining, evolving, and enforcing design, documentation, and release standards.

• Establish and normalize best-in-class DFx principles across products, platforms, and suppliers, ensuring manufacturability and quality.

• Lead hands-on mechanical engineering efforts across the full product lifecycle, from concept development through production readiness and sustaining, for assigned priority programs.

• Actively coach and mentor peer designers through ongoing design critiques, feedback, and constructive technical challenges to elevate engineering capability.

• Own and drive Design for Manufacturability (DFM) and broader DFx execution, working directly with suppliers on part design, tooling strategies, and process optimization.

• Lead and facilitate design reviews and technical forums that raise the engineering bar and promote a culture of continuous improvement.

• Develop and execute robust test plans and reporting to verify designs meet performance, quality, regulatory, and reliability requirements.

• Coordinate closely with manufacturing and supply chain to support build qualification, production release, and post-launch design improvements.

• Manage regulatory and quality documentation in alignment with Byrna's quality system and applicable industry standards.

• Identify systemic design, manufacturability, and process risks, proactively implementing cross-program improvements and best practices.

📝 Enhancement Note: The responsibilities emphasize both "player" (hands-on execution, DFx leadership) and "coach" (mentorship, standards development, culture building) aspects. The breakdown suggests a significant focus on establishing and enforcing organizational-level design standards and fostering engineering talent.

🎓 Skills & Qualifications

Education: Bachelor's degree in Mechanical Engineering or a closely related engineering discipline.

Experience: 15+ years of progressive mechanical design experience, with a strong emphasis on executing DFM/DFx on consumer or industrial products manufactured at scale. Experience in regulated or compliance-sensitive consumer products is preferred.

Required Skills:

• Demonstrated experience establishing or owning design standards, design guidelines, or DFx playbooks at an organizational level.

• Proven ability to coach, mentor, or formally develop other mechanical engineers through structured design reviews and written feedback.

• Proficiency in CAD software, Geometric Dimensioning and Tolerancing (GD&T) per ASME Y14.5, tolerance stack-up analysis, and Failure Mode and Effects Analysis (FMEA), specifically Design FMEA (DFMEA).

• Experience leading end-to-end product development from concept through production release, including ownership of technical data packages.

• Demonstrated experience as an external-facing technical interface with component and tooling suppliers, including direct DFM engagement.

Preferred Skills:

• Experience with injection molding, die casting, or similar high-volume manufacturing processes.

• Prior formal coaching, technical training development, or design instructor experience.

📝 Enhancement Note: The requirement for establishing organizational-level design standards and formal mentorship experience highlights the leadership and strategic aspects of this role, beyond typical senior engineering duties. Eligibility for export-controlled technology access is a critical compliance requirement.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Documented examples of established organizational design standards, design guidelines, or DFx playbooks that you authored or led.

• Case studies showcasing your direct involvement in DFM/DFx efforts for scaled consumer or industrial products, detailing process improvements and resulting efficiencies.

• Evidence of your coaching or mentorship activities, such as examples of structured design review feedback provided to junior engineers or developed training materials.

• Technical data packages from products you led through the full lifecycle, demonstrating comprehensive documentation and release processes.

Process Documentation:

• Examples of written design standards, design guidelines, or reusable design exemplars that you have developed.

• Documentation outlining your approach to establishing and enforcing DFx principles across multiple product lines or suppliers.

• Records of facilitating design reviews and technical forums, including methodologies for raising the engineering bar and promoting best practices.

• Examples of how you have identified and mitigated systemic design, manufacturability, or process risks across programs.

📝 Enhancement Note: Candidates should prepare to showcase artifacts demonstrating their ability to influence organizational processes, not just project-specific outcomes. This includes formal documentation, training materials, and evidence of systemic risk mitigation.

💵 Compensation & Benefits

Salary Range: $175,000 - $185,000 annually.

Benefits:

• Comprehensive health, dental, and vision insurance plans.

• Retirement savings plan with company match (e.g., 401k).

• Paid time off, including vacation, sick leave, and holidays.

• Potential for performance-based bonuses or stock options.

• Opportunities for professional development and continued learning.

Working Hours: Standard full-time hours, typically 40 hours per week. The role involves a significant hands-on component (approx. 60% of time) which may require focused, dedicated blocks of time, while the mentorship aspect (approx. 40%) allows for flexible interaction and guidance.

📝 Enhancement Note: The salary range provided is specific and competitive for a senior principal-level engineering role in the Massachusetts area. Benefits are standard but should be confirmed for specifics like 401k match percentages and PTO accrual rates. The work hours are noted as standard but the split responsibilities imply a need for effective time management and dedication to both individual contribution and team development.

🎯 Team & Company Context

🏢 Company Culture

Industry: Defense Technology / Security Products. Byrna Technologies Inc. specializes in non-lethal personal defense solutions, operating in a sector that requires high standards for product safety, reliability, and regulatory compliance.

Company Size: The provided data does not specify company size, but the context of a "senior principal engineering authority" and a focus on elevating an R&D organization suggests a growing company with established product lines and ambitious development goals. This often implies a dynamic environment where individual impact is highly visible.

Founded: The founding date is not provided, but the company is actively developing and launching new products, indicating a mature yet evolving organization.

Team Structure:

• The role reports to the VP, New Product Development and R&D, indicating a direct line to senior leadership within the product development function.

• The primary collaborators include R&D, Manufacturing, Quality, Supply Chain, Operations, Regulatory/Compliance, and Program Management, highlighting a cross-functional operational environment.

• The position acts as a key technical interface with external suppliers and manufacturing partners, emphasizing the importance of strong external relationships.

Methodology:

• Data-driven decision-making is expected, particularly in design validation and risk assessment.

• Workflow planning and optimization are central to the role's responsibility for establishing and enforcing design and DFx standards.

• Automation and efficiency are implied through the focus on manufacturability and process optimization with suppliers.

Company Website: www.byrna.com

📝 Enhancement Note: As Byrna operates in a sensitive sector, the company culture likely emphasizes discipline, precision, and adherence to rigorous quality and compliance standards. The growth phase implies opportunities for individuals to shape processes and contribute significantly to the company's engineering maturity.

📈 Career & Growth Analysis

Operations Career Level: This is a "Senior Principal" level role, signifying a high degree of technical expertise and influence. It is positioned as a senior engineering authority, often a career pinnacle for individual contributors who excel technically and can mentor others, rather than moving into direct people management. The role requires deep subject matter expertise in mechanical design, DFx, and product development lifecycles.

Reporting Structure: Reporting directly to the VP of New Product Development and R&D places this role at a strategic level within the organization, with direct access to senior leadership for technical direction and influence.

Operations Impact: The role's impact is significant, directly influencing product quality, manufacturability, reliability, and cost through the establishment and enforcement of design standards. By elevating engineering capability, it contributes to faster, more efficient product development cycles and reduces long-term product issues and costs. This role is critical for building a scalable and robust R&D foundation.

Growth Opportunities:

• Technical Specialization: Deepen expertise in advanced DFx methodologies, materials science, or specific manufacturing processes relevant to Byrna's product lines.

• Process Development Leadership: Lead initiatives to further refine and evolve Byrna's entire product development process, from conceptualization through to sustaining engineering.

• Cross-Functional Influence: Expand influence across manufacturing, quality, and operations to drive holistic product excellence and operational efficiency.

• Mentorship and Training: Develop formal training programs and establish best practices that can be scaled across the engineering organization, potentially leading to a role focused on engineering enablement.

📝 Enhancement Note: This role represents a significant career step for an experienced engineer who wants to remain deeply technical while influencing organizational practices and mentoring others. The growth path is focused on deepening technical mastery and expanding strategic influence rather than traditional management progression.

🌐 Work Environment

Office Type: Primarily office and engineering lab-based. This suggests a professional environment with dedicated spaces for design work, analysis, and testing.

Office Location(s): Andover, MA. This location offers access to a skilled engineering talent pool and is part of the broader Boston technology corridor.

Workspace Context:

• Collaborative Environment: While hands-on work is emphasized, the role requires close collaboration with R&D, manufacturing, quality, and supply chain teams. Expect regular cross-functional meetings and design reviews.

• Operations Tools and Technology: Access to advanced CAD software, simulation tools, and engineering lab equipment will be essential for design execution and validation.

• Team Interaction: Opportunities for direct interaction with peers, junior engineers, and senior leadership (VP of R&D) are integral to the role's coaching and strategic oversight functions.

Work Schedule: The role is full-time (40 hours/week) and on-site. While standard hours apply, the "player-coach" dynamic and hands-on nature may necessitate focused work periods and flexibility to meet project deadlines and mentorship needs.

📝 Enhancement Note: The on-site requirement suggests a preference for hands-on collaboration and immediate access to lab facilities. The Andover location is a strong hub for engineering talent.

📄 Application & Portfolio Review Process

Interview Process:

• Initial Screening: A review of your resume and portfolio to assess alignment with the required technical skills, experience in DFx/DFM, and mentorship capabilities.

• Technical Interview(s): Deep dives into your mechanical design expertise, CAD proficiency, GD&T understanding, DFMEA experience, and past product development cycles. Expect scenario-based questions related to design challenges and problem-solving.

• DFx/Standards Interview: Focus on your experience in establishing and enforcing design standards, your approach to DFx, and how you would coach engineers on these principles. This may involve discussing past examples of DFx playbooks or design guidelines you've developed.

• Leadership/Mentorship Interview: Assessment of your coaching style, ability to influence without authority, and experience in developing engineering talent. Behavioral questions will explore how you handle constructive feedback and foster a positive engineering culture.

• Case Study/Portfolio Review: You may be asked to present specific projects from your portfolio, detailing your role, the challenges faced, the solutions implemented, and the impact on manufacturability, quality, and cost. This is where you demonstrate your ability to articulate complex technical details and process improvements.

• Final Interview: Potentially with senior leadership (e.g., VP of R&D) to assess overall fit, strategic thinking, and alignment with Byrna's vision.

Portfolio Review Tips:

• Showcase Organizational Impact: Highlight examples where you've influenced company-wide design standards or DFx processes, not just project-specific achievements. This could include formal documentation you created or led.

• Quantify Results: Whenever possible, use metrics to demonstrate the impact of your DFM/DFx efforts (e.g., reduction in manufacturing defects, improved yield, cost savings, faster time-to-market).

• Detail Your Coaching Approach: Include examples of how you've mentored engineers, provided feedback, and helped them improve their design skills.

• Structure Your Case Studies: For each project, clearly outline the problem, your approach, the specific tools and methodologies used (CAD, GD&T, DFMEA, tolerance analysis), challenges encountered, solutions, and outcomes.

• Demonstrate DFx Breadth: Showcase experience with various DFx principles (manufacturability, assembly, testability, reliability, serviceability) as applied to relevant manufacturing processes (e.g., injection molding, die casting).

Challenge Preparation:

• Be ready to discuss hypothetical scenarios related to establishing new design standards or improving the DFx process in a growing R&D organization.

• Prepare to explain complex technical concepts (like tolerance stack-ups or DFMEA) clearly and concisely, as you would to engineers with varying levels of experience.

• Practice articulating your leadership philosophy and how you foster a culture of technical excellence and continuous improvement.

📝 Enhancement Note: Candidates should anticipate a rigorous interview process that heavily emphasizes both deep technical expertise and the ability to lead and mentor. The portfolio should be curated to specifically address the organizational-level impact and coaching aspects of the role.

🛠 Tools & Technology Stack

Primary Tools:

• CAD Software: Proficiency in industry-standard CAD packages (e.g., SolidWorks, CATIA, Inventor, Creo) for mechanical design and detailed part creation.

• Analysis Tools: Experience with tolerance stack-up analysis software and Finite Element Analysis (FEA) tools for performance and stress simulations.

• DFx Software/Methodologies: Familiarity with tools or frameworks that support DFx analysis, though often this is integrated into CAD or performed through structured reviews.

Analytics & Reporting:

• DFMEA Tools: Experience with software or structured templates for conducting and documenting Failure Mode and Effects Analysis.

• Data Analysis: Ability to analyze test data, manufacturing yields, and defect reports to identify systemic issues and drive process improvements.

• Technical Documentation: Proficiency in creating and managing technical data packages, design guidelines, and standards documentation.

CRM & Automation:

• While not a direct CRM role, understanding how design data flows into ERP/PLM systems for manufacturing and supply chain is crucial.

• Familiarity with project management tools (e.g., Jira, Asana, MS Project) for tracking design tasks and program progress.

📝 Enhancement Note: The emphasis is on core mechanical engineering design and analysis tools, with a strong focus on documentation, standards, and processes that facilitate manufacturability and quality. Proficiency in specific CAD/CAE software will be assessed.

👥 Team Culture & Values

Operations Values:

• Technical Excellence: A commitment to rigorous engineering practices, high-quality design, and data-driven decision-making.

• Accountability & Ownership: Taking responsibility for product designs from concept through production, ensuring reliability and manufacturability.

• Continuous Improvement: A dedication to refining processes, learning from mistakes, and constantly elevating engineering standards and capabilities.

• Collaboration & Mentorship: Fostering a supportive environment where knowledge is shared, and team members are developed to their full potential.

• Integrity & Compliance: Adherence to quality systems, regulatory requirements, and export control policies.

Collaboration Style:

• Cross-Functional Integration: Proactive engagement with manufacturing, quality, supply chain, and program management to ensure design alignment with operational realities.

• Constructive Feedback: A culture that encourages open, honest, and technically grounded feedback during design reviews and team discussions.

• Knowledge Sharing: Emphasis on developing and disseminating best practices, design guidelines, and lessons learned across the engineering team.

📝 Enhancement Note: The culture at Byrna, given its industry and the role's requirements, likely values precision, discipline, and a strong ethical compass. The emphasis on "player-coach" suggests a collaborative spirit where senior members actively support the growth of others.

⚡ Challenges & Growth Opportunities

Challenges:

• Balancing Hands-On vs. Coaching: Effectively managing time and energy between deep technical design work (60%) and mentorship/standards development (40%) requires strong organizational skills and prioritization.

• Influencing Without Direct Authority: Persuading peers and other departments to adopt new standards or processes requires strong technical credibility, communication skills, and strategic influence.

• Scaling Engineering Practices: Establishing and ensuring consistent adoption of design standards across a potentially growing R&D team presents an ongoing challenge.

• Navigating a Dynamic Industry: Staying current with evolving manufacturing technologies, material science, and regulatory requirements in the defense/security product space.

Learning & Development Opportunities:

• Advanced DFx Techniques: Opportunities to explore and implement cutting-edge DFx methodologies and tools.

• Process Leadership: Take the lead in defining and refining Byrna's product development lifecycle and engineering best practices.

• Cross-Functional Expertise: Gain deeper insights into manufacturing, quality assurance, and supply chain operations through close collaboration.

• Industry Best Practices: Attend relevant industry conferences, workshops, and training sessions to stay abreast of advancements in mechanical design and manufacturing.

📝 Enhancement Note: This role presents challenges that are typical for senior individual contributors looking to expand their impact beyond individual projects. The growth opportunities are geared towards deepening technical mastery and expanding strategic influence.

💡 Interview Preparation

Strategy Questions:

• "Describe a time you established a new design standard or DFx guideline for an engineering team. What was your process, and how did you ensure adoption?"

• "How would you coach a junior engineer who is struggling with GD&T or tolerance analysis?"

• "What is your approach to leading a critical design review for a high-priority product nearing production?"

Company & Culture Questions:

• "What interests you about Byrna Technologies and our mission?"

• "How do you foster a culture of continuous improvement and technical excellence within an engineering team?"

• "Describe your experience working with suppliers on DFM issues. How do you ensure alignment with company policies, including export control?"

Portfolio Presentation Strategy:

• Focus on Impact: Select 2-3 key projects that best demonstrate your ability to implement DFx, improve manufacturability, and elevate design standards.

• Quantify Achievements: For each project, clearly articulate the problem, your specific contribution, the processes/tools used, and the measurable outcomes (e.g., percentage reduction in defects, cost savings, performance improvements).

• Showcase Mentorship: Be prepared to discuss specific instances where you mentored engineers, provided feedback, and helped them grow their skills. If you have developed training materials, have examples ready.

• Explain Your Process: Clearly articulate your methodology for design reviews, DFx implementation, and documentation. Be ready to explain your approach to tolerance stack-ups, GD&T, and DFMEA.

📝 Enhancement Note: Interview preparation should focus on showcasing leadership in process development and mentorship, alongside technical prowess. Candidates should be ready to provide concrete examples that align with Byrna's stated needs for elevated engineering capability and design rigor.

📌 Application Steps

To apply for this Senior Principal Design Manager position:

• Submit your application through the provided link on Paycom.

• Curate Your Portfolio: Select 2-3 impactful projects that clearly demonstrate your expertise in DFx, DFM, organizational standards development, and engineering mentorship. Quantify the results of your work with specific metrics wherever possible.

• Tailor Your Resume: Highlight experience related to establishing design standards, coaching engineers, leading product development lifecycles, and supplier DFM engagement. Use keywords from the job description.

• Prepare for Technical Depth: Brush up on core mechanical engineering principles, CAD proficiency, GD&T, tolerance analysis, and DFMEA. Be ready to discuss your approach to design reviews and technical problem-solving.

• Research Byrna Technologies: Understand their product lines, market position, and the importance of safety and reliability in their industry. This will help you tailor your responses and demonstrate genuine interest.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and operations industry-standard assumptions. All details should be verified directly with the hiring organization before making application decisions.

---