About this role
Essential Duties & Responsibilities:
Materials Engineering
· Evaluate and support the selection of composite materials, including carbon fiber, fiberglass, aramid fibers, core materials, adhesives, and resin systems.
· Develop, maintain, and update material specifications, standards, and qualification requirements.
· Perform material testing and characterization to verify mechanical, thermal, and environmental performance.
· Review supplier-provided material data and support material qualification and approval processes.
· Assess material alternatives by comparing performance, manufacturability, availability, and cost to recommend the most suitable solution for each application.
· Support the evaluation, qualification, and implementation of new materials and advanced composite technologies to improve product performance and manufacturability.
Process Engineering
· Develop, document, and improve composite manufacturing processes.
· Establish process specifications, manufacturing instructions, and quality requirements.
· Support manufacturing methods including:
o Hand layup
o Vacuum bagging
o Resin infusion (VARTM)
o Resin Transfer Molding (RTM)
o Compression molding
o Injection molding
o Prepreg layup
o Autoclave curing
o Oven curing
o Composite assembly and bonding
· Define critical process parameters and process control methods.
· Support process validation and qualification activities.
Manufacturing Support
· Provide day-to-day technical support to production operations.
· Investigate manufacturing issues involving defects, yield loss, porosity, delamination, dimensional variation, or cure-related concerns.
· Lead root cause investigations and corrective action implementation.
· Collaborate with operators and supervisors to improve process consistency and productivity.
· Support manufacturing readiness activities for new product introduction (NPI).
Testing & Failure Analysis
· Coordinate and perform material and process validation testing.
· Analyze failures related to composite structures, bonding, environmental exposure, and manufacturing defects.
· Prepare technical reports summarizing findings and recommendations.
· Support qualification testing for customer and regulatory requirements.
Continuous Improvement
· Identify opportunities to reduce scrap, rework, cycle time, and manufacturing costs.
· Apply Lean Manufacturing and Six Sigma methodologies to process improvement projects.
· Analyze manufacturing and quality data to improve process capability and repeatability.
· Support automation and advanced manufacturing initiatives.
· Support customer technical reviews and audits when required.
Qualifications & Experience:
Education:
· Bachelor's degree in Materials Science, Mechanical Engineering, Aerospace Engineering, Chemical Engineering, Manufacturing Engineering, or a related discipline.
Experience:
· 2+ years of experience in composites engineering, manufacturing engineering, materials engineering, or a related role.
· Experience with composite manufacturing processes and materials.
· Knowledge of polymer matrix composites and composite fabrication methods.
· Experience interpreting engineering drawings and technical specifications.
· Familiarity with manufacturing documentation, process controls, and quality systems.
Preferred Qualifications:
· Experience in aerospace, defense, energy, industrial equipment, marine, automotive, or sporting goods industries.
· Familiarity with composite material testing standards (ASTM, ISO, SAE, or equivalent)
· Understanding of composite inspection methods including ultrasonic and non-destructive testing (NDT)
· Experience performing failure analysis and root cause investigations.
· Exposure to Lean Manufacturing, Six Sigma, or continuous improvement methodologies.
· Strong analytical and troubleshooting skills.
· Excellent written and verbal communication skills
Key Competencies
· Hands-on engineering approach
· Technical curiosity and continuous learning
· Structured problem solving
· Strong attention to detail
· Cross-functional collaboration
· Project management
· Initiative and accountability
· Customer-focused mindset
Technical Skills:
Materials Knowledge
· Carbon fiber composites.
· Fiberglass composites.
· Thermoset resin systems
· Epoxy systems
· Vinyl ester resins
· Core materials and adhesives
· Composite bonding technologies
Process Knowledge
· Vacuum infusion
· Autoclave processing
· Prepreg manufacturing
· Cure cycle development
· Process validation
· Tooling and fixture development
· Manufacturing process controls
Analytical Tools
· Root Cause Analysis (5 Why, Fishbone, 8D)
· Statistical Process Control (SPC)
· PFMEA
· Design of Experiments (DOE)
· Data analysis and reporting
Physical Requirements & Work Environment:
· Lab and office-based role with visits to manufacturing sites as needed.
· Stand or walk for extended periods.
· Occasionally lift items weighing up to 20 pounds.
· Adherence to all safety policies, procedures, and regulatory requirements is mandatory.