Weld Manufacturing Engineer

Insight Global is hiring for a high-speed aircraft manufacturer focused on the rapid design, build, and test of high-Mach and hypersonic aircraft for the national interest.

As a Welding Manufacturing Engineer, you will play a critical role in enabling rapid development, fabrication, and integration of advanced hardware across our R&D and prototype manufacturing environments. You’ll be responsible for developing weld processes, fixtures, and joint designs that bridge early design concepts to flight-ready hardware. This position is hands-on and deeply cross-functional, working directly with design, manufacturing, and test teams to bring complex systems from concept to reality.

Responsibilities

• Develop, qualify, and optimize weld processes and parameters for multiple techniques including, but not limited to, electron beam, laser beam, gas tungsten arc, gas metal arc, plasma arc, resistance, friction-stir, and orbital tube welding.
• Support R&D and production builds of welded aircraft structures, tanks, and propulsion assemblies, providing direct guidance to technicians and manufacturing engineers.
• Collaborate with design and manufacturing engineering to drive weld joint design, fixture development, and assembly methods optimized for manufacturability, precision, and repeatability.
• Lead root cause investigations related to weld performance, material compatibility, and process deviations; implement corrective actions based on metallurgical and mechanical findings.
• Plan and execute weld qualification campaigns, including mechanical testing, NDE inspection, and data interpretation.
• Partner with NDE specialists to evaluate weld quality and develop advanced inspection techniques tailored for high-performance aircraft applications.
• Implement process control improvements using feedback from weld tests, NDE, and production data to increase reliability and consistency.
• Identify and integrate automated or robotic welding solutions to improve throughput, consistency, and quality.
• Research and evaluate emerging welding technologies and materials for potential application in hypersonic vehicle manufacturing.
• Collaborate closely with tooling, automation, and integration teams to develop solutions that minimize distortion, improve accuracy, and accelerate production timelines.

Basic Qualifications

• Bachelor’s degree in Mechanical Engineering or other related technical discipline.
• Hands-on fabrication, manufacturing, or testing experience with welded aerospace assemblies.
• Strong understanding of weld design principles and mechanical tolerances under thermal and structural loads.

Preferred Skills and Experience

• Master’s degree in Welding Engineering or related technical field.
• Hands-on welding experience with nickel-based alloys, stainless steel, titanium, copper, and aluminum.
• Experience with brazing, joining, and metallographic interpretation.
• Deep understanding of welding processes including, but not limited to, electron beam, laser beam, plasma arc, resistance, friction-stir, gas tungsten arc, and gas metal arc.
• Robot programming experience for automated welding applications.
• Tooling design experience for welded assemblies to minimize distortion and improve repeatability.
• Knowledge of weld strength testing methodologies, standards, and data acquisition systems (ASTM E8, E399, E740, ISO 15653, AWS D17.X, AWS C7.X, thermocouples, strain gages, etc.).
• Experience performing root cause analysis and corrective actions using techniques such as optical and SEM fractography, hardness testing, chemical analysis, and mechanical testing.
• Demonstrated success applying Design for Manufacturability (DFM) principles to transition welded designs from prototype to production.
• Strong ability to multi-task, prioritize, and communicate results across engineering, manufacturing, and leadership teams.
• Highly detail-oriented with excellent documentation and organizational skills.
• Proven track record of success in fast-paced, high-growth, technically demanding environments.