Composite Materials & Process Engineer

Composite Materials & Process Engineer

Job Category:
Engineering

Full-Time

Headquarters Houston, TX 77075, USA

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

Materials Knowledge:

Carbon fiber composites.

Fiberglass composites.

Thermoset resin systems

Epoxy systems

Vinyl ester resins

Core materials and adhesives

Composite bonding technologies

Process Knowledge:

Vacuum infusion

Autoclave processing

Prepreg manufacturing

Cure cycle development

Process validation

Tooling and fixture development

Manufacturing process controls

Analytical Tools:

Root Cause Analysis (5 Why, Fishbone, 8D)

Statistical Process Control (SPC)

PFMEA

Design of Experiments (DOE)

Data analysis and reporting

Physical Requirements & Work Environment:

Lab and office-based role with visits to manufacturing sites as needed.

Stand or walk for extended periods.

Occasionally lift items weighing up to 20 pounds.

Adherence to all safety policies, procedures, and regulatory requirements is mandatory.

Equal Opportunity Employer This employer is required to notify all applicants of their rights pursuant to federal employment laws. For further information, please review the Know Your Rights notice from the Department of Labor.