Composite Materials & Process Engineer

Job Title

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 curiosity and continuous learning

· Structured problem solving

· Strong attention to detail

· Cross-functional collaboration

· Project management

· Initiative and accountability

· Customer-focused mindset

Technical

Skills:

Materials Knowledge:

· Carbon fiber composites.

· Fiberglass…