In the high-tech world of automation, robotics, and smart manufacturing, the Controls Engineer is a critical player. They are the architects of the automated systems that power modern industry, from automotive assembly lines to pharmaceutical production. If you're drawn to a career that blends electrical engineering, computer science, and mechanical systems, you’ll be pleased to know it's not only intellectually stimulating but also financially rewarding. A skilled controls engineer can expect to earn a competitive salary, with top professionals commanding well over $130,000 annually.
This guide provides a data-driven look at what you can expect to earn as a controls engineer in 2024 and beyond. We'll break down the average salaries and explore the key factors that can significantly impact your paycheck.
What Does a Controls Engineer Do?
Before diving into the numbers, it's essential to understand the role. In short, a controls engineer designs, develops, installs, and manages the equipment and systems used to monitor and control machinery and processes. They are the "brains" behind the brawn of automation.
Key responsibilities often include:
- Designing and developing control systems: Creating electrical schematics and system layouts.
- Programming PLCs (Programmable Logic Controllers): Writing the logic that dictates how machines operate, using platforms like Rockwell (Allen-Bradley) or Siemens.
- Developing HMIs (Human-Machine Interfaces): Creating the graphical screens that allow operators to interact with and monitor the machinery.
- Integrating sensors, motors, and robotics: Ensuring all hardware components communicate and work together seamlessly.
- Troubleshooting and commissioning: Testing systems on-site, debugging code, and ensuring the final product meets project specifications.
It's a dynamic role that requires a unique mix of hands-on technical skill and high-level system design.
Average Controls Engineer Salary
According to recent data from leading salary aggregators, the average base salary for a Controls Engineer in the United States falls into a strong range.
- Payscale.com reports the average base salary for a Controls Engineer is approximately $85,500 per year. The typical range spans from $65,000 for entry-level positions to over $118,000 for experienced professionals (Source: Payscale, 2024).
- Salary.com places the median salary slightly higher, at around $95,210 per year, with a common salary band falling between $85,468 and $105,435 (Source: Salary.com, 2024).
- Glassdoor calculates a total pay average (including base salary and additional compensation like bonuses) of $104,749 per year, with a "likely range" of $86,000 to $129,000 (Source: Glassdoor, 2024).
These figures highlight a healthy earning potential, but your individual salary will be determined by several key factors.
Key Factors That Influence Salary
Your specific background, location, and career choices will have the most significant impact on your earnings. Let's break down the most important variables.
### Level of Education
A Bachelor of Science degree is the standard entry point for a controls engineering career, typically in Electrical Engineering (BSEE), Mechanical Engineering (BSME), or Chemical Engineering (BSChE). However, further education can open doors to higher pay and more specialized roles.
- Bachelor's Degree: This is the foundational requirement and will qualify you for the majority of controls engineering positions.
- Master's Degree (M.S.): An M.S. in a relevant field, particularly one focused on control theory or mechatronics, can lead to a higher starting salary. It often qualifies candidates for R&D positions or roles that require advanced mathematical modeling and system analysis, which typically command higher pay.
- Certifications: While not a formal degree, professional certifications can significantly boost your value. A Professional Engineer (PE) license is highly respected and can lead to a salary increase. Vendor-specific certifications from companies like Rockwell, Siemens, or robotics manufacturers (e.g., FANUC) also demonstrate valuable expertise.
### Years of Experience
Experience is arguably the single most powerful factor in determining your salary. As you gain practical skills and a proven track record of successful projects, your earning potential grows substantially.
- Entry-Level (0-3 years): Engineers new to the field can expect to earn in the $65,000 to $85,000 range. The focus at this stage is on learning foundational skills, programming basic systems, and supporting senior engineers.
- Mid-Career (4-9 years): With solid experience, engineers take on more project responsibility, lead smaller teams, and tackle more complex systems. Salaries typically move into the $85,000 to $115,000 range.
- Senior / Lead (10+ years): Senior controls engineers are often subject matter experts. They design system architecture, mentor junior engineers, and manage large-scale, critical projects. Their salaries often exceed $115,000 and can reach $140,000 or more, especially if they have specialized expertise.
### Geographic Location
Where you work matters. Salaries are adjusted for local cost of living and the concentration of industries that rely on automation. Metropolitan areas with strong manufacturing, tech, or energy sectors tend to offer the highest salaries.
Top-Paying States/Metropolitan Areas:
- California (San Jose, San Francisco): The tech and semiconductor industries drive high demand and salaries that can be 20-30% above the national average.
- Texas (Houston, Austin): The oil & gas, energy, and burgeoning tech manufacturing sectors make Texas a lucrative state for controls engineers.
- Massachusetts (Boston): A hub for biotech, robotics, and defense contracting.
- Michigan (Detroit Metro): The heart of the American automotive industry consistently has high demand for automation and controls expertise.
Conversely, states with a lower cost of living and less industrial concentration will typically offer salaries closer to the lower end of the national average.
### Company Type
The type of company you work for plays a major role in your compensation and daily work life.
- System Integrators: These firms design and build custom automation solutions for a variety of clients. The work is project-based and often involves travel, but can offer excellent pay, especially with overtime.
- Original Equipment Manufacturers (OEMs): At an OEM, you'll work on the control systems for a specific line of machinery that the company produces and sells. It offers stability and deep product expertise.
- End-Users (Manufacturing Plants, Utilities): Working directly for a company like a car manufacturer, food processor, or power plant involves maintaining, troubleshooting, and upgrading existing systems. These roles often come with excellent benefits and work-life balance.
- Tech, R&D, and Aerospace: Companies at the cutting edge of technology (e.g., Tesla, Amazon, SpaceX, Boston Dynamics) often pay a significant premium to attract top-tier talent for their advanced robotics and automation needs. These are often the highest-paying roles in the field.
### Area of Specialization
While all controls engineers share a common skill set, specializing in a high-demand niche can make you a more valuable—and higher-paid—asset.
- PLC/HMI Programming: This is the core skill, but deep expertise in a popular platform like Rockwell's Studio 5000 or Siemens' TIA Portal is always in demand.
- Robotics: Engineers who can integrate and program industrial robots (FANUC, KUKA, ABB) are highly sought after as robotic automation explodes across industries.
- Distributed Control Systems (DCS): Specializing in DCS (e.g., Emerson DeltaV, Honeywell Experion) is extremely valuable in large process-based industries like oil & gas, chemical manufacturing, and power generation, leading to very high salaries.
- Machine Vision & IIoT: Expertise in integrating cameras for quality inspection or connecting systems to the Industrial Internet of Things (IIoT) for data analysis are cutting-edge skills that command a premium.
Job Outlook
The future for controls engineers is bright. The push for increased efficiency, improved quality, on-shoring of manufacturing, and the rise of Industry 4.0 and smart factories ensures a sustained and growing demand for automation professionals.
While the U.S. Bureau of Labor Statistics (BLS) does not have a separate category for "Controls Engineer," it groups them with closely related professions like Electrical and Electronics Engineers. For this group, the BLS projects a job growth of 5% from 2022 to 2032, which is faster than the average for all occupations. The median annual wage for this category was $104,610 as of May 2023 (Source: BLS Occupational Outlook Handbook). This strong outlook confirms that a career in controls is a stable and secure choice for the future.
Conclusion
A career as a controls engineer offers a powerful combination of challenging, impactful work and excellent financial rewards.
Key Takeaways:
- Strong Earning Potential: The average salary is robust, typically ranging from $85,000 to over $105,000, with significant room for growth.
- Experience is King: Your salary will increase substantially as you move from an entry-level position to a senior-level expert.
- Location and Specialization Matter: Working in a high-demand industry or geographic hub, and developing niche skills in areas like robotics or DCS, can dramatically boost your income.
- Excellent Job Security: The unstoppable trend toward automation ensures that your skills will remain in high demand for years to come.
For students and professionals looking for a dynamic and future-proof engineering career, the path of a controls engineer is not just a job—it's a gateway to becoming a key architect of the future of technology and industry.