Senior Engineer Special Processes

Job Description:

At EDGE bold ideas are engineered into technologies that protect, improve and save lives.

Headquartered in the United Arab Emirates, EDGE is a leading advanced technology group working at the forefront of defence and emerging technologies. Spanning more than 35 specialised companies and multiple centres of excellence, we are purpose-built to move fast. Free from heavy legacy processes, we give our people the autonomy, accountability, and agility to bring breakthrough technologies from concept to reality.

Based in Abu Dhabi, a globally connected hub at the crossroads of Europe, Asia, Africa, and the Middle East, EDGE is home to a truly multicultural community where bold ideas thrive, and the future is shaped.

Together, we are shaping the future.

The Special Processes Senior Engineer is a senior technical and team-leading role responsible for developing, qualifying, and industrializing critical aerospace special processes supporting Powertech’s propulsion programs, including turbofan, microjet, and piston engines.

The role acts as the technical authority for special process technologies, supporting greenfield manufacturing setup, New Product Introduction (NPI), production industrialization, and process capability development. The Senior Engineer works closely with Manufacturing Engineering, Design Engineering, Quality, Supply Chain, suppliers, equipment vendors, and technology partners while providing day-to-day technical leadership to engineers and technicians within the special processes team.

Special Process Development & Industrialization

• Lead the development, qualification, and continuous improvement of aerospace special processes for rotating, structural, and hot-section engine components.
• Provide technical leadership in processes including:
  • Shot peening
  • Thermal spray coatings (HVOF, plasma spray, wear-resistant and environmental coatings)
  • Heat treatment, vacuum heat treatment, solution treatment, aging, and stress relief
  • Brazing
  • Surface preparation, grit blasting, masking, and finishing processes
  • Cleaning
  • Chemical processing
• Define and review manufacturing routings, process specifications, work instructions, control plans, and acceptance criteria.
• Establish process capability requirements and statistical monitoring methods to ensure stable and repeatable production performance.
• Lead process validation activities including First Article Inspection (FAI), industrial qualification, capability studies, and production readiness reviews.

Greenfield Manufacturing Capability Development

• Support the establishment of in-house special process capabilities, including facility layout, equipment specification, supplier selection, commissioning, and process qualification.
• Define equipment requirements, utility needs, process controls, and environmental requirements for new special process cells.
• Support make-versus-buy evaluations and phased capability development strategies aligned with product and production roadmaps.
• Coordinate technology transfer activities from external partners and suppliers into Powertech manufacturing operations.

NPI & Program Execution

• Lead special process engineering activities during New Product Introduction (NPI) from prototype development through production readiness.
• Support manufacturing planning, process qualification, and production ramp-up activities for new engine programs and component families.
• Act as the special process focal point for assigned engine modules, components, and development programs.
• Ensure process readiness aligns with program schedules, quality requirements, and certification objectives.

Design-to-Manufacture & Concurrent Engineering

• Support concurrent engineering activities with design teams to ensure…