Prototype Fabrication Specialist

Job Description Summary

The Prototype Fabrication Specialist will build, rework, repair, and test prototype aircraft generators, power conversion boxes, and wiring harnesses in a development and lab environment. This role supports new product introduction and technology maturation by converting engineering concepts and designs into high-quality hardware used in laboratory testing and demonstration. Position is located at the EPISCenter in Dayton, OH.

• Prototype build, rework, and repair
  • Build, rework, and repair prototype aircraft generators, including stators, rotors, and associated subassemblies.
  • Build, rework, and repair power conversion boxes and related electro‑mechanical assemblies.
  • Fabricate, assemble, and rework wiring and cable harnesses to support prototype systems and test setups.
  • Perform hands‑on assembly, integration, and troubleshooting of prototype hardware in an R&D and lab environment.
• Installation, test, and support equipment
  • Install, instrument, and prepare prototype hardware for laboratory and rig testing.
  • Build, install, and test support equipment, including but not limited to circuit boards, cable harnesses, test fixtures, and hydraulic or pneumatic support systems.
  • Operate standard lab and shop equipment (hand tools, power tools, meters, oscilloscopes, test stands) to support development testing.
• Technical interpretation and execution
  • Read, interpret, and apply electrical schematics, mechanical drawings, assembly drawings, and wiring diagrams to complete assigned tasks.
  • Leverage prior designs, build records, and best practices where appropriate to improve quality and efficiency.
  • Provide feedback to engineers and designers on design-for-assembly, manufacturability, and serviceability based on hands‑on build experience.
• Collaboration, communication, and documentation
  • Communicate status, technical issues, and risks clearly and promptly to project leaders, engineers, and management.
  • Work closely with engineering, test, and manufacturing teams to clarify requirements and resolve technical issues.
  • Document build steps, test setups, test results, and nonconformances in accordance with internal procedures.
  • Maintain accurate records, travelers, and build logs to ensure traceability and repeatability.
• Safety, quality, delivery, and cost
  • Follow all safety procedures, lab practices, and EHS requirements when working with high voltage, rotating machinery, and test equipment.
  • Ensure work is performed on schedule, within budget, and to required quality standards.
  • Support continuous improvement activities in the lab, including 5S, standard work, and process improvements.

• Associate’s Degree in a technical field (electro‑mechanical, electronics, industrial, or related) from an accredited institution and a minimum of 2 years of experience in electro‑mechanical equipment fabrication, troubleshooting, or maintenance;
• Or a high school diploma or GED with a minimum of 4 years of military or industrial experience in electro‑mechanical equipment fabrication, troubleshooting, or maintenance.

• Hands‑on electro‑mechanical experience in the fabrication, design, development, or maintenance of power generation equipment (generators, motors, alternators, or similar rotating machinery).
• Familiarity with IPC standards such as IPC‑J‑STD, IPC‑610, and IPC‑620 for soldering and cable or harness assembly.
• Ability to organize, clarify, and interpret technical requirements from drawings, specifications, and procedures.
• Technical writing experience, including the ability to document build procedures, test setups, and test results clearly.
• Experience using AutoCAD or other CAD tools to review drawings, mark up changes, or support simple layout updates.
• Strong oral and written communication skills with a demonstrated ability to work effectively in a cross‑functional team environment.
• Proficiency with MS Office tools (Excel, Word, PowerPoint, Outlook) for reporting and communication.
• Light machining and sheet metal experience (drilling, tapping, cutting, basic fixture fabrication) preferred.
• Motor or generator winding experience is a strong plus.
• Demonstrate…