Engineer Material Process 3

Engineer Material Process 3 (Principal / Sr. Principal Materials and Process Engineer)

This role offers the opportunity to shape advanced materials and manufacturing solutions that support high-reliability aerospace and defense products. As a Materials and Process Engineer, you will define and qualify materials, processes, and manufacturing methods for metallic components, ensuring they meet stringent engineering, contractual, and regulatory requirements. You will collaborate closely with design, manufacturing, suppliers, and laboratory teams to drive robust, repeatable processes, resolve complex material and process issues, and maintain high standards of quality, safety, and performance.

• Define engineering requirements for parts, materials, processes, manufacturing technologies, machinery, tools, and automation systems used in product design and production, ensuring alignment with contractual and regulatory obligations.
• Select, develop, or recommend metallic materials and associated processes that meet performance, reliability, and manufacturability requirements.
• Qualify new materials, parts, and processes to meet engineering and program requirements, including planning and executing qualification test and audit programs.
• Manage and support test and audit programs to qualify suppliers to applicable material and process requirements.
• Support engineering design reviews by providing materials and process expertise, including evaluation of metallic parts and manufacturing processes.
• Participate in and support failure analyses for metallic parts and processes, working with cross-functional teams to identify root causes and recommend corrective actions.
• Assist in supplier qualification activities, including reviewing supplier capabilities, processes, and documentation to ensure compliance with requirements.
• Respond to routine supplier technical inquiries and escalate complex supplier or production issues to senior Materials and Process engineers as needed.
• Perform analyses to characterize material and process performance, including evaluation of tool, material, part, or process failures.
• Recommend corrective actions for material, process, or manufacturing issues and prepare them for senior engineering review and approval.
• Coordinate and support laboratory activities such as metallography, hardness testing, tensile testing, and non-destructive testing/inspection (NDT/NDI).
• Compile and organize test data from laboratory activities for interpretation, engineering disposition, and documentation.
• Apply project management practices to plan and execute assigned tasks, ensuring cost, technical, and schedule requirements are met.
• Incorporate Environmental, Health and Safety (EHS), LEAN, and Quality principles into materials and process work, lab activities, and procedures.
• Support the creation, review, and revision of material and process specifications, work instructions, and test plans to ensure alignment with internal and industry standards.
• Support investigations of non-conformances and supplier deviations by collecting evidence, performing basic root-cause analysis, and drafting corrective action recommendations.
• Maintain accurate engineering records, including test reports, engineering orders, and related documentation, and support configuration control and design reviews.
• Communicate technical findings, analysis results, and recommendations clearly to cross-functional teams, stakeholders, and leadership.
• Interact frequently with manufacturing floors, supplier facilities, and testing laboratories to support process implementation, troubleshooting, and continuous improvement.
• Travel occasionally to supplier sites, test facilities, and other locations as required to support engineering, qualification, and troubleshooting activities.
• Comply with all applicable security, health, and safety policies while performing engineering and lab activities.

• 5 years of engineering experience with a Bachelor of Science in a STEM discipline, preferably in Materials Science and Engineering; or 3 years of Materials Science and Engineering experience with a Master's degree; or 1 year with a PhD for Principal-level consideration.
• 8 years of engineering experience with a Bachelor of Science in a STEM discipline, preferably in Materials Science and Engineering; or 6 years of Materials Science and Engineering experience with a Master's degree; or 4 years with a PhD for Sr. Principal-level consideration.
• Engineering experience in aerospace, defense, or other high-reliability manufacturing environments.
• Practical knowledge of metallurgy for ferrous and nonferrous alloys, including heat treatment basics, corrosion and fatigue fundamentals, and common materials testing methods.
• Hands-on exposure to metallographic sample preparation and basic laboratory techniques such as cutting, polishing, etching, and hardness testing.
• At least 2 years of experience with manufacturing processes such as machining, forging, forming, fastening,…