Composite Materials & Process Engineer

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.