Composites 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:
• Hand layup
• Vacuum bagging
• Resin infusion (VARTM)
• Resin Transfer Molding (RTM)
• Compression molding
• Injection molding
• Prepreg layup
• Autoclave curing
• Oven curing
• 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.