| Location | Littleton, CO |
| Salary | $110,000–$135,000 |
ExoTerra is a world leader in solar electric propulsion systems and space exploration satellites. The company develops Hall Thrusters, propulsion modules, microsatellites and launch vehicle upper stages. We have been awarded multiple propulsion module and satellite contracts.
We are seeking a highly skilled and results-driven Process Engineer to lead the development, industrialization, and ramp-up of coil winding manufacturing processes for a new high-rate aerospace production facility. This role is critical in establishing robust, scalable, and efficient processes that meet stringent aerospace quality, cost, and delivery requirements.
The ideal candidate will have deep experience in coil winding process design, production ramp, and aerospace/precision manufacturing environments, with a strong focus on throughput optimization, quality assurance, and lean principles.
• Lead design and implementation of coil winding manufacturing processes for a new aerospace production site.
• Define end-to-end workflows for coil fabrication: wire handling, winding, insulation, potting/encapsulation, and electrical testing.
• Support facility layout planning, optimizing winding cell configuration, material flow, and curing areas.
• Develop and validate processes for precision coil winding, including tension control and insulation systems.
• Author work instructions and SOPs; establish process controls for aerospace standards (AS9100).
• Select and qualify winding equipment, tensioners, and automation solutions.
• Conduct capability studies (Cp, Cpk) for critical parameters: turn count, resistance, inductance, hi-pot.
• Lead production ramp-up to achieve rate, yield, and cost targets.
• Identify and eliminate bottlenecks in winding, curing, and test operations.
• Apply lean techniques (takt time, line balancing, value stream mapping) and Six Sigma methods to reduce scrap and improve throughput.
• Ensure processes meet aerospace and electrical testing requirements (hi-pot, insulation resistance, continuity).
• Support FAI and qualification builds; lead root cause investigations for winding defects.
• Implement error-proofing and robust quality controls.
• Partner with Electrical Engineering, Design, Supply Chain, Quality, and Operations teams.
• Support supplier development for magnet wire, insulation materials, and potting compounds.
• Provide technical input during design reviews, advocating for coil manufacturability.
• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Electrical Engineering, or related field.
• 5–10+ years of experience in manufacturing/process engineering, preferably in aerospace or regulated industries.
• Proven experience in launching new production lines or facilities.
• Strong knowledge of high-rate production environments and process scaling.
• Experience with lean manufacturing, Six Sigma, or continuous improvement methodologies.
• Familiarity with aerospace quality systems (AS9100, NADCAP).
• Experience with process validation, PFMEA, control plans, and statistical process control (SPC).
• Experience with coil winding, transformer, or motor manufacturing processes.
• Excellent verbal and written communication skills.
• Experience with Spacecraft Fabrication and Test.
• Experience with non-conformance resolution.
• Experience with manufacturing process development.
• Experience with programming or automation systems.
To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.