Carbon Fiber Composites Design & Process Development Engineer

Carbon Fiber Composites Design & Process Development Engineer Position Summary

We are seeking a highly motivated and experienced Carbon Fiber Composites Design and Process Development Engineer to lead the design, analysis, and manufacturing process improvements of carbon fiber composite parts and vessels. In this role, you will drive both research and high‑volume production initiatives, bridging the gap between innovative concept development and efficient manufacturing for advanced composite systems.

• Design and develop carbon fiber composite parts and vessels, ensuring optimal strength-to-weight ratios and durability.
• Perform mechanics of materials and structural analysis of composite systems using ANSYS or other advanced simulation tools.
• Translate layup design into bulk anisotropic composite property estimates.
• Develop, validate, and optimize composite manufacturing processes—from tooling and fixture design to layup, curing, and machining—to meet rigorous quality and throughput goals.
• Lead R&D initiatives as well as high-volume production efforts, seamlessly transitioning concepts to production‑scale applications.
• Collaborate with cross-functional teams including design, materials science, quality, and production to select composite systems and validate performance.
• Create detailed work instructions, process documentation, and quality protocols that ensure consistency and adherence to industry standards.
• Identify opportunities for continuous improvement, applying lean manufacturing and statistical process control methodologies.
• Mentor junior engineers and technicians, and provide technical leadership during process troubleshooting and corrective action implementation.

• Education:
  
  Bachelor’s degree (BS) in Materials Science, Mechanical Engineering, or a related field with a minimum of 10 years’ experience, or a Master’s degree (MS) or higher with at least 5 years’ relevant experience.
• Demonstrated expertise in carbon fiber composite design and the mechanics of composite materials.
• Proven experience in structural analysis, particularly with simulation tools such as ANSYS or equivalent.
• Extensive background in developing and improving composite manufacturing processes in both R&D and high throughput production environments.
• Excellent communication, teamwork, and problem-solving skills.

• Advanced understanding of composite processing techniques (e.g., autoclave curing, resin infusion, precision layup) and quality assurance methodologies.
• Experience with CAD/CAM software for tooling and fixture development.
• Familiarity with lean manufacturing principles or Six Sigma practices.
• A proactive, hands‑on approach with strong analytical and technical aptitude.

• Ability to obtain and maintain required DOE and/or NRC security access authorization.

Edgewater is committed to recruiting and maintaining a staff of highly skilled professionals to support our customers. We offer highly competitive salaries and employee benefit packages structured to best suit your needs. We offer multiple individual and family benefit options including paid time off, medical, dental, life, vision, and disability insurance, and a pre‑ and post‑tax 401(k) retirement account with Company matching contributions and 100% vesting for eligible participants beginning DAY 1.

Edgewater is an equal opportunity employer and all qualified applicants will be considered for employment without regard to race, color, religion, sex, national origin, protected veterans, or individuals with disabilities in accordance with EO 14173.