Aerospace Manufacturing Engineer – Composite Structures

We’re ALTEN Technology USA, an engineering company that provides solutions for engineering, technology, and product development projects. For decades, we’ve been helping our clients develop products that are changing the world, whether that’s by shaping the future of space exploration, saving lives with medical devices that set a new standard of care, or creating the fully autonomous electric taxi of tomorrow. Our team of more than 600 people works across industries including aerospace, medical devices and life sciences, unmanned systems and robotics, automotive OEM and tier 1 suppliers, commercial vehicle, electric vehicles, rail, and more. Our offices across the US have different industry focuses and engage with our clients in different ways, ranging from working on-site at client facilities to performing product development at our delivery centers.

ALTEN Group, our parent company, has been a leader in engineering and information technology for more than 30 years. ALTEN Group operates in 30 countries across Europe, North America, Asia, Africa and the Middle East and employs more than 36,000 people, 88% of whom are engineers. The company covers the whole development cycle and offers a choice of service levels, from technology consulting to complete project outsourcing.

When you join ALTEN Technology USA, you join a group of people passionate about collaborating to solve some of the world’s most technical engineering challenges. Our success is tied to taking care of our employees by building relationships and providing opportunities for mentorship and career growth. We offer comprehensive benefits for all full-time employees, including medical, dental, and vision insurance; a 401(k) plan with employer matching; paid time off (PTO); paid parental leave; and mentorship to help you take your career to the next level. You don’t have to take our word for it that we are a great place to work—we were named on the 2023 Top Workplaces list thanks to feedback from our proud employees.

Job Description:

The Ground Test Division designs, manufactures, and services test equipment supporting development and aftermarket engine programs for major engine manufacturers. This role involves supporting the manufacturing of final-level assemblies, subcomponents, and structural details, with a strong focus on composite fabrication and process development.

The engineer will be responsible for developing manufacturing processes, tooling concepts, and repair methodologies for composite components using approved engineering models and drawings. The role also supports production activities, troubleshooting, process improvements, and manufacturing readiness for build schedules ranging from three to six months.

This position requires strong experience in composite manufacturing, mechanical fabrication processes, tooling, and aerospace-grade manufacturing standards.

Key Responsibilities

Manufacturing Process Development

• Develop and improve manufacturing processes and tooling for composite part fabrication
• Create manufacturing instructions, bills of materials, and purchase specifications based on engineering drawings and technical requirements
• Support manufacturability reviews and recommend process improvements
• Ensure compliance with established engineering methodologies and manufacturing standards

Composite Manufacturing & Repair

• Support fabrication of advanced composite and bonded structures using fiberglass, aramid, carbon prepreg, and wet layup processes
• Develop and validate repair processes in collaboration with design teams
• Evaluate operational damage and determine acceptable repair solutions
• Support curing, bonding, adhesive application, surface preparation, and autoclave/oven operations

Production & Engineering Support

• Provide manufacturing support throughout conceptual, preliminary, and detailed design phases
• Work closely with production teams to support validation, manufacturing, and operational service activities
• Train production personnel on new manufacturing processes and techniques
• Review and disposition non-conforming materials against technical requirements

Quality & Continuous Improvement

• Contribute to Cost of Poor Quality (COPQ) reduction initiatives
• Support PFMEA implementation and continuous process improvement activities
• Use engineering analysis and technical judgment to resolve manufacturing challenges
• Support troubleshooting and root cause analysis for production-related issues

Cross-Functional Collaboration

• Collaborate with design, manufacturing, and operations teams
• Support material selection activities based on manufacturing compatibility and usability
• Coordinate with internal and external stakeholders to ensure manufacturing readiness and schedule adherence

Required Qualifications

• Bachelor’s degree in STEM (Science, Technology, Engineering, or Mathematics) with:
• Minimum 10 years of relevant experience, OR
• Advanced degree with minimum 8 years of relevant experience
• Experience with mechanical manufacturing processes including machining, welding, joints, and fastening methods
• Strong knowledge of GD&T and engineering drawing interpretation
• Hands-on experience with fiber-reinforced polymer composites:
• Fiberglass
• Aramid
• Carbon prepreg
• Wet layup processes
• Experience with advanced composite manufacturing processes:
• Fiber reinforcement
• Bonding and adhesives
• Surface preparation
• Ovens and autoclaves
• Strong troubleshooting, analytical, and problem-solving skills
• Strong project ownership and execution mindset

Preferred Qualifications

• Experience with Creo/Windchill, NX, FiberSIM, or Teamcenter
• Familiarity with Non-Destructive Testing (NDT) methods such as:
• Ultrasonic testing
• Eddy current
• FPI
• X-ray inspection
• Experience with Design for Manufacturing & Assembly (DFMA)
• Understanding of manufacturing cost optimization and reproducibility
• Experience implementing PFMEA methodologies
• Aerospace, defense, automotive, or similar industry background

ALTEN Technology is an Equal Opportunity Employer. Our Policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of an individual’s age, race, color, sex, religion, national origin, disability, sexual orientation, gender identity/expression or veteran status.

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