Materials And Process Engineer

Job Title: Material & Process Engineer

Location: Chandler, AZ

Position Overview

We are seeking an experienced Materials & Process / Materials Science Engineer to support sustaining activities for legacy aerospace programs and contribute to future development initiatives, including a new cabin interior program.

The ideal candidate will possess deep expertise in aerospace materials, manufacturing processes, regulatory compliance, and certification standards to ensure materials and processes meet the demanding safety, performance, and regulatory requirements associated with high-performance jet-powered aircraft.

Key Responsibilities

Materials & Process Engineering

• Evaluate current airframe materials for obsolescence, cost reduction opportunities, and performance enhancements.
• Conduct comparative analyses of existing and alternative manufacturing processes, assessing impacts on strength, durability, fatigue life, and other critical performance parameters.
• Perform risk assessments and develop mitigation strategies related to materials and manufacturing processes.

Manufacturing Process Development

• Develop, maintain, and improve manufacturing and engineering processes, including machining, forming, welding, heat treatment, chemical milling, and composite fabrication.
• Create and maintain detailed process specifications, work instructions, and quality control procedures to support consistent production outcomes.
• Drive lean manufacturing and cost-reduction initiatives to improve operational efficiency.

Failure Analysis & Continuous Improvement

• Investigate material failures and quality concerns using root cause analysis methodologies.
• Implement corrective and preventive actions to improve product reliability and manufacturing performance.

Cross-Functional Collaboration

• Partner with design engineering teams to improve manufacturability, optimize material utilization, reduce weight, and control production costs.
• Provide technical materials expertise during design reviews and support engineering changes for manufacturing optimization.

Regulatory & Certification Support

• Maintain detailed documentation related to material specifications, testing, and process controls to support FAA certification requirements.
• Ensure compliance with evolving aerospace regulations and industry standards.
• Collaborate with FAA DERs and certification authorities as needed.

Data Management & Analysis

• Manage materials databases, FEA packages, and statistical analysis tools for engineering evaluations.
• Support analytical assessments related to material performance and process validation.

Qualifications

Education

• Bachelor’s or Master’s degree in Mechanical Engineering, Materials Science & Engineering, Aerospace Engineering, or a related field.

Required Experience

• Minimum of 7 years of aerospace industry experience.
• Strong knowledge of aerospace material properties and testing methodologies, including metallic alloys, composites, polymers, and coatings.
• Experience with corrosion testing and evaluation, including stress corrosion, galvanic compatibility, and intergranular corrosion.
• Experience with corrosion prevention techniques and environmental testing such as UV exposure, thermal cycling, humidity resistance, and chemical compatibility.
• Experience supporting or leading design allowable programs.
• Strong interpersonal skills with the ability to manage multiple projects simultaneously.
• Experience working with FAA DERs and certification authorities.

Preferred Experience

• Broad exposure to aircraft development programs involving structures, systems, and interiors for high-performance aircraft.
• Additive manufacturing experience.
• Experience with CATIA V5, Siemens NX, and Teamcenter PLM.
• Familiarity with Agile development tools such as Jira and Confluence.

Core Competencies

• Strong analytical and problem-solving skills with the ability to evaluate complex technical challenges.
• Excellent verbal and written communication skills with the ability to present technical information effectively.
• Collaborative team player with strong interpersonal and cross-functional communication abilities.

Preferred Qualifications

• Knowledge of honeycomb sandwich panel construction methods and joining techniques, including bonded joints, inserts, and panel pins.
• Strong understanding of aerospace fastening methods and manufacturing best practices.
• Experience operating testing equipment such as load frames, burn cabinets, and environmental chambers.