Design Engineer

Design Engineer Pacific Aero Tech – A Gardner Standard Portfolio Company

Location:

Kent, WA

Reports To:

Director of Engineering

Gardner Standard is supporting one of its portfolio companies, Pacific Aero Tech, in the search for a hands‑on Design Engineer to support advanced aerospace repair development and FAA‑certified engineering programs.

Pacific Aero Tech (PAT) is an FAA Part 145 Repair Station specializing in aerospace transparencies and advanced repair development. This role is not a support engineer position. The Design & R&D Engineer is fully accountable for designing, leading, and delivering FAA‑approved DER development programs for new and existing aircraft window repairs from concept definition through certification, production release, and sustainment.

This engineer will own technical direction, drive R&D experimentation, author and defend substantiation, and deliver compliant engineering data packages that enable PAT to launch new repair capabilities and scale production safely and profitably.

This role requires strong judgment, regulatory fluency, hands‑on experimentation capability, and the ability to work independently in a Part 145 environment.

• Lead full lifecycle DER development programs for new repair designs and processes:
• Problem definition and certification strategy
• Experimental design and test planning
• Tooling and fixture design
• Data generation, analysis, and substantiation
• FAA‑compliant documentation and approval support
• Serve as the technical focal point between PAT, DERs, FAA, suppliers, and internal stakeholders.
• Ensure engineering data meets 14 CFR, FAA guidance, airworthiness, and safety requirements for Part 145 repairs.
• Maintain audit‑ready documentation and traceability throughout the program lifecycle.

• Design and execute R&D experiments to validate new repair methods, materials, tooling, and processes.
• Build and test prototype parts, assemblies, and fixtures; analyze results and iterate designs.
• Develop and validate process parameters (thermal, mechanical, material, electrical as applicable).
• Translate experimental outcomes into repeatable, production‑ready engineering solutions.
• Produce engineering drawings, models, and data packages using Solid Works.
• Apply GD&T per ASME Y14.5 to all critical features and interfaces.
• Define specifications, acceptance criteria, and standards for repair processes and tooling.
• Support or author engineering substantiation, including test reports, analysis, and compliance narratives.

• Convert approved DER data into shop‑floor‑ready work instructions, inspection criteria, and training materials.
• Support production during initial implementation and ramp‑up of new repairs.
• Troubleshoot technical issues in manufacturing and drive corrective engineering actions.
• Ensure new designs are robust, repeatable, auditable, and cost‑effective.

• Operate with high independence and sound engineering judgment.
• Mentor technicians and junior engineers on design intent, process discipline, and compliance.
• Drive decisions using data, risk assessment, and regulatory awareness—not trial‑and‑error guessing.

• Bachelor’s degree in Mechanical, Materials, Aerospace, or Electrical Engineering (ABET‑accredited).
• 5+ years of hands‑on engineering experience in aerospace, preferably in Part 145 or Part 21 environments.
• Demonstrated experience leading R&D or certification‑driven engineering projects, not just supporting them.
• Strong proficiency in Solid Works and engineering documentation.
• Working knowledge of FAA regulations, DER processes, and conformity expectations.
• Proven ability to design experiments, analyze results, and defend technical conclusions.
• Comfortable working in manufacturing, lab, and shop environments.

• Existing FAA DER designation (Structures, Repairs, or Systems), or strong eligibility path.
• Experience with aerospace transparencies, bonded structures, or complex assemblies.
• Prior responsibility for authoring or defending…