Senior Manufacturing Engineer

Job Title:

Senior Manufacturing Engineer

Location:

Bedfordshire

The Manufacturing Engineer designs, implements, and optimizes large‑scale Wire Arc Additive Manufacturing processes for aerospace components. This role focuses on the development of processes for complex, near‑net‑shape metallic structures from design to production, ensuring strict compliance with aviation quality and safety standards.

• Process Development:
  Establish, validate, and optimize WAAM deposition parameters (current, voltage, travel speed, shielding gas flow) for aerospace alloys like Titanium, Inconel, and Aluminium.
• Path Planning & Simulation:
  Utilize specialized additive software to generate, simulate, and optimize multi‑axis robot/CNC deposition paths to prevent collisions and minimize thermal distortion.
• Thermal Management:
  Design and execute thermal control strategies, including inter‑pass temperature monitoring and in‑process cooling, to manage residual stress and microstructural integrity.
• NPI Support:
  Lead New Product Introduction (NPI) by transforming aerospace CAD models into WAAM‑optimized, near‑net‑shape geometries ready for post‑process machining.
• Equipment Integration:
  Program, configure, and maintain integrated WAAM cells, including robotic manipulators (ABB), power sources (Fronius) and environmental enclosures.
• Quality &
  
  Qualification:
  
  Ensure all manufacturing processes conform to aerospace standards such as AS9100 and emerging additive manufacturing regulations (e.g., ASTM F42, SAE AMS
  7039).

• Additive Software:
  High proficiency in WAAM‑specific slicing and path‑generation software.
• Robotics & Automation:
  Competence in programming multi‑axis industrial robots and integrating sensor feedback loops for real‑time process monitoring.
• Aerospace Metallurgy:
  Deep understanding of solidification mechanics, phase transformations, and defect generation (porosity, cracking) in wire‑fed arc deposition.
• Subtractive Integration:
  Strong knowledge of how WAAM near‑net shapes interface with subsequent precision CNC machining operations.
• Root Cause Analysis:
  Mastery of problem‑solving frameworks (8D, FMEA, 5 Whys) to troubleshoot deposition anomalies and microstructural defects.

Eligibility:
Hold or be eligible to hold SC clearance.