Composite 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: o Hand layup o Vacuum bagging o Resin infusion (VARTM) o Resin Transfer Molding (RTM) o Compression molding o Injection molding o Prepreg layup o Autoclave curing o Oven curing o 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 curios…