In the high-tech world of automation, robotics, and smart manufacturing, controls engineers are the essential architects of efficiency and precision. This critical role not only offers a dynamic and challenging career path but also boasts significant financial rewards. For those considering this field, the salary potential is compelling, with average earnings comfortably exceeding the national average and top professionals commanding six-figure incomes.
This article provides a data-driven analysis of what you can expect to earn as a controls engineer, exploring the key factors that shape your salary and the promising future of this profession.
What Does a Controls Engineer Do?
Before diving into the numbers, it's important to understand the role. A controls engineer is a specialized type of engineer who designs, develops, installs, and manages the systems and equipment used to monitor and control machinery and processes. They are the masterminds behind automation.
Their core responsibilities often include:
- Programming Programmable Logic Controllers (PLCs): These are the industrial computers that form the brains of most automated systems.
- Developing Human-Machine Interfaces (HMIs): They create the graphical screens and dashboards that allow operators to interact with the machinery.
- Integrating Robotics: They program and implement robots for tasks like assembly, welding, and material handling.
- Designing Control Systems: They create the electrical schematics and system architecture for new automated processes.
- Troubleshooting and Optimization: They diagnose issues, fine-tune systems for peak performance, and ensure operational safety.
Controls engineers are vital in industries like manufacturing, automotive, aerospace, pharmaceuticals, energy, and food and beverage.
Average Controls Engineer Salary
Salary data shows that a career as a controls engineer is financially lucrative. While figures vary based on several factors, we can establish a reliable baseline from trusted sources.
According to data synthesized from major salary aggregators, the average base salary for a controls engineer in the United States typically falls between $85,000 and $105,000 per year.
- Salary.com reports the median salary for a mid-level Controls Engineer (Engineer II) to be around $95,590 as of late 2023, with the top 10% earning over $118,000.
- Payscale lists a median salary of approximately $84,000, emphasizing that this can grow significantly with experience and specialized skills.
- Glassdoor places the average total pay (including bonuses and profit sharing) around $98,000 per year.
The overall salary range is wide, reflecting the career's growth potential. Entry-level positions may start around $70,000, while senior-level or principal controls engineers with specialized expertise can earn well over $130,000 to $150,000 annually.
Key Factors That Influence Salary
Your specific salary as a controls engineer is not a single number but a spectrum influenced by a combination of critical factors. Understanding these elements is key to maximizing your earning potential.
### Level of Education
A bachelor's degree in a relevant engineering field is the standard entry requirement. The most common degrees are:
- Electrical Engineering (BSEE)
- Mechanical Engineering (BSME)
- Chemical Engineering (for process control)
- Computer Engineering
While a bachelor's degree will open the door, a Master of Science (M.S.) in a field like Control Systems Engineering or a related discipline can provide a significant advantage. Graduates with a master's degree often command higher starting salaries and may be fast-tracked into research & development (R&D) or advanced systems design roles, which typically pay more. Furthermore, holding a Professional Engineer (PE) license can provide a substantial salary boost and is often required for senior consulting or public sector roles.
### Years of Experience
Experience is arguably the most significant factor in determining a controls engineer's salary. The career path has a clear and rewarding progression.
- Entry-Level (0-2 years): Engineers new to the field are learning the ropes of PLC programming, reading electrical schematics, and assisting on projects. Expect a salary range of $65,000 to $80,000.
- Mid-Level (3-7 years): At this stage, engineers can manage small projects independently, design control systems from scratch, and troubleshoot complex issues. Their salary typically rises to the $80,000 to $110,000 range.
- Senior/Lead (8+ years): A senior controls engineer leads large-scale projects, mentors junior engineers, and develops company-wide automation strategies. Their expertise is highly valued, with salaries often ranging from $110,000 to $140,000+. Principal engineers or technical managers can exceed this range.
### Geographic Location
Where you work matters. Salaries are adjusted for local market demand and cost of living. Metropolitan areas with a high concentration of technology, manufacturing, or energy companies tend to offer the highest salaries.
High-Paying Metropolitan Areas:
- San Jose, CA
- San Francisco, CA
- Houston, TX (strong in oil, gas, and process control)
- Boston, MA
- Seattle, WA
Conversely, salaries may be closer to the national average or slightly below in regions with a lower cost of living or less industrial concentration. However, these roles can still offer an excellent quality of life.
### Company Type
The type of company you work for directly impacts your compensation package.
- Large Corporations (OEMs & End-Users): Companies in sectors like automotive, aerospace, pharmaceuticals, or consumer goods often have large in-house controls engineering teams. They typically offer competitive salaries, excellent benefits, and structured career paths.
- System Integrators: These are specialized firms that design and build custom automation solutions for various clients. While base salaries might sometimes be slightly lower than at large corporations, the potential for overtime pay, bonuses, and exposure to diverse technologies can be very high.
- Tech and R&D Firms: Engineers working on cutting-edge robotics, machine vision, or AI-driven control systems at technology companies often command top-tier salaries due to the specialized skills required.
- Energy and Utilities: Roles involving Distributed Control Systems (DCS) in oil and gas, chemical processing, or power generation are famously high-paying due to the complexity and critical nature of the operations.
### Area of Specialization
Within controls engineering, certain specializations are in higher demand and can lead to increased earnings. While PLC/HMI programming is the foundational skill, expertise in the following areas can make you a more valuable candidate:
- Robotics Integration: Expertise in programming and integrating industrial robots (from brands like FANUC, KUKA, or ABB) is highly sought after.
- Machine Vision Systems: Implementing camera-based systems for quality inspection and guidance is a high-value skill.
- Distributed Control Systems (DCS): This skill is crucial for large-scale process industries and is often associated with higher pay scales.
- SCADA Systems: Expertise in Supervisory Control and Data Acquisition (SCADA) systems is vital for infrastructure and utility sectors.
Job Outlook
The future for controls engineers is exceptionally bright. The U.S. Bureau of Labor Statistics (BLS) projects that employment for Electrical and Electronics Engineers—the broader category under which most controls engineers fall—is expected to grow by 5% from 2022 to 2032, which is faster than the average for all occupations.
This growth is fueled by powerful global trends, including:
- The rise of Industry 4.0 and smart factories.
- Increased investment in industrial automation and robotics to improve efficiency and competitiveness.
- The expansion of renewable energy systems (wind, solar) which require sophisticated control systems.
- Advancements in electric vehicles and battery manufacturing.
As long as industries seek to automate processes, improve quality, and enhance safety, the demand for skilled controls engineers will remain strong.
Conclusion
A career as a controls engineer offers a powerful combination of intellectual stimulation, hands-on problem-solving, and excellent financial compensation. With a median salary hovering near the six-figure mark and a clear path for advancement, it represents a stable and rewarding profession.
For those aspiring to enter or advance in this field, the key takeaways are clear:
- Build a strong foundation with a relevant engineering degree.
- Gain hands-on experience, as it is the primary driver of salary growth.
- Cultivate specialized skills in high-demand areas like robotics or advanced control systems.
- Be strategic about location and industry, as both can significantly impact your earning potential.
By focusing on these areas, you can engineer not only sophisticated automated systems but also a successful and prosperous career.