Engineer

Overview of the Position:

The Engineer I is responsible for supporting the development, validation, documentation, and implementation of component repair processes, test methods, fixtures, tooling, and engineering solutions used in the overhaul and repair of aircraft components. This position works closely with quality, operations, technicians, inspectors, outside engineering resources, OEM data, and DER support to develop practical and compliant repair methods in accordance with regulatory, customer, and internal requirements. The role supports troubleshooting, minor repair development, substantiation activities, process improvement, and introduction of new repair capabilities, equipment, and test methods.

Essential Duties and Responsibilities:

• Supports the development and implementation of new and existing repair processes for aircraft components in accordance with approved technical data, regulatory requirements, and internal procedures.
• Assists in developing minor repairs, repair instructions, process sheets, work instructions, and technical documentation for component maintenance, overhaul, and restoration activities.
• Supports DER repair development activities by gathering technical data, inspection results, dimensional information, material requirements, photographs, sketches, and test results needed for substantiation packages.
• Reviews component discrepancies, damage conditions, and failure modes to determine repair feasibility, disposition paths, and engineering recommendations.
• Works with technicians, inspectors, and quality personnel to troubleshoot component issues, test failures, dimensional nonconformances, assembly problems, and repeated shop findings.
• Evaluates serviceability limits, wear patterns, fits, finishes, clearances, and functional performance of component parts during repair development and troubleshooting.
• Develops, improves, and validates repair fixtures, holding tools, gages, test adapters, assembly aids, and production support tooling required for maintenance and repair operations.
• Assists in setup, qualification, validation, and implementation of new shop equipment, machines, test stands, and special process support equipment.
• Supports creation of test procedures, acceptance criteria, setup instructions, and validation plans for new or revised repair and test methods.
• Participates in first article, trial repair, feasibility, and proof-of-concept activities to verify repair process capability and repeatability.
• Assists with engineering evaluation of rejected or scrap candidate parts to determine whether recovery through approved repair is possible.
• Interprets drawings, manuals, CMMs, OEM data, process specifications, service bulletins, and engineering standards to support repair development activity.
• Prepares sketches, marked-up drawings, simple CAD layouts, and supporting technical documents as needed to communicate repair intent and tooling concepts.
• Supports the design and documentation of fixture concepts for machining, inspection, leak testing, assembly, flow testing, electrical testing, and functional testing.
• Coordinates with outside vendors, machine shops, test labs, and engineering service providers regarding tooling, testing, special processing, material review, or repair substantiation needs.
• Assists in identifying replacement materials, equivalent hardware, alternate processes, and manufacturing methods where technically acceptable and compliant.
• Supports root cause investigations and corrective actions related to repair failures, repeated discrepancies, nonconforming product, shop escapes, and customer returns.
• Participates in validation of repaired components through dimensional inspection, functional testing, fit checks, pressure testing, electrical testing, or other applicable acceptance methods.
• Reviews field, shop, and customer feedback to identify recurring component issues and opportunities for repair improvement or reliability enhancement.
• Assists in development of capability expansion projects for new part numbers, new component families, and new repair technologies.
• Supports engineering changes associated with new tooling, revised dimensions, process improvements, or updated repair instructions.
• Maintains organized engineering records, validation data, development logs, test results, and document revisions associated with repair development work.
• Works with quality and document control to release, revise, and maintain controlled engineering documents in support of production use.
• Supports internal and external audits by providing engineering records, substantiation support, process rationale, and technical explanations related to repairs and tooling.
• Assists in ensuring repair development activities are aligned with FAA, EASA, customer, OEM, and company quality system requirements.
• Performs other engineering and repair development duties as assigned in support of company objectives.

Other Knowledge, Skills, and Abilities:

• Basic understanding of aircraft component repair, overhaul, inspection, and functional testing processes.
• Familiarity with mechanical assemblies, dimensional inspection methods, tolerancing, fits, finishes, and technical drawing interpretation.
• Ability to troubleshoot technical issues using inspection data, test results, observations, and engineering judgment.
• Working knowledge of common manufacturing and repair methods such as machining, polishing, grinding, honing, blending, bonding, welding, cleaning, assembly, and testing.
• Ability to read and interpret CMMs, engineering drawings, specifications, manuals, and standards.
• Familiarity with fixture design, tooling concepts, and test setup development.
• Ability to communicate clearly with technicians, inspectors, quality personnel, management, and external engineering resources.
• Strong organizational skills and ability to manage multiple development tasks in a regulated environment.
• Proficiency in Microsoft Office and ability to prepare technical reports, repair instructions, and engineering summaries.
• CAD experience or ability to support basic fixture and tooling layout development preferred.
• Familiarity with FAA Part 145, quality systems, and repair station documentation practices preferred.

Education / Experience Requirements:

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Mechanical Engineering Technology, or related engineering discipline preferred.
• Equivalent technical experience in aircraft component repair development, manufacturing engineering, quality engineering, or MRO engineering may be considered.
• Fresh Graduate with relevant engineering, repair development, manufacturing, or aircraft component support experience preferred.

Other Qualifications:

• Ability to exercise sound technical judgment while working in a regulated aerospace repair environment.
• Ability to support engineering projects from concept through validation and implementation.
• Ability to work effectively in a cross-functional team environment and support production as needed.

Physical Demands and Work Environment:

• Is occasionally required to stand; walk; reach with hands and arms; stoop, kneel, crouch, and crawl; and lift up to 25 pounds.
• May be required to work in shop, laboratory, and office environments in support of troubleshooting, fixture validation, and equipment setup.
• Is regularly required to sit and use hands to finger, handle, or feel.
• Is frequently required to talk or listen.
• Works in moderate noise levels.