Aerospace Engineer - Thermal Spray

Location: Windsor, CT (on-site) |
Travel: Occasional |
Type: Full-time, Direct Hire

*** RELOCATION ASSISTANCE IS PROVIDED***

Our client is a global engineering and solutions company and a leading provider of aftermarket parts, repairs, and solutions that extend the life of aircraft engines and gas turbines. They develop, manufacture, and repair critical turbine components for a range of engine platforms in the aerospace, energy, and defense industries.

Their engineers learn from top industry experts, work with advanced technologies, and help keep aircraft flying safely around the world.

• Medical, dental, vision, EAP, and wellness incentives, all starting on day one
• 401(k) with employer matching
• PTO, sick time, paid holidays, and parental leave, all available from day one
• Regular performance conversations, a training curriculum, and engineering fellowship programs
• Competitive pay with quarterly and annual bonus eligibility

Our client is looking for a Thermal Spray Process Engineer to support the repair and overhaul of critical gas turbine engine components for commercial aerospace. In this role you will develop, optimize, and sustain processes for:

• Surface preparation
• Masking
• Thermal spray coating
• Robotic programming
• Process control

Your work will directly affect product quality, turnaround time, delivery, and operational efficiency.

• Develop, implement, and optimize thermal spray coating processes for aerospace gas turbine components
• Support production every day: monitor yield, reduce rework, and improve process capability
• Find root causes and put corrective actions in place so process and quality issues don't come back
• Make sure thermal spray equipment and related process technologies are ready for production
• Design and implement tooling, fixtures, gauging, and process improvements that make the work safer, better, and faster
• Program and optimize 6-axis robotic systems used in thermal spray
• Develop spray parameters for new coating materials and keep improving existing processes
• Develop and optimize masking and surface preparation methods, including grit blasting
• Create and maintain SOPs, work instructions, process specs, calibration instructions, training materials, and quality records
• Train operators and work with maintenance on preventive maintenance programs
• Take part in Kaizen, Lean, and continuous improvement initiatives
• Use Six Sigma and DMAIC to solve complex manufacturing problems

• Bachelor's degree in Engineering or a related science such as Materials Science, Chemistry, or Physics
• 3+ years of engineering experience in manufacturing; aerospace MRO or gas turbine experience preferred
• Experience supporting manufacturing operations, process development, and continuous improvement
• Knowledge of root cause analysis, corrective action systems, and statistical problem-solving
• Familiarity with Lean Manufacturing and structured problem-solving
• Strong written and verbal communication with operations, quality, engineering, and maintenance teams

• Thermal spray equipment and coating process development experience
• Experience programming 6-axis robots
• 3D CAD experience, such as Siemens NX
• Knowledge of APS, Dual Wire Arc Spray, and Combustion Spray
• Aerospace masking and fixture design experience
• Knowledge of surface prep and grit blasting requirements
• Aerospace component repair, overhaul, or manufacturing experience
• Lean Six Sigma Green Belt or Kaizen participation
• Familiarity with aerospace quality systems and process control
• Work happens both in the office and on the production floor, around production equipment and industrial processes
• You will work regularly in production areas, labs, and repair operations
• You must be able to stand, walk, bend, and reach for long periods and occasionally lift up to 25 lbs
• PPE and compliance with safety policies are required
• Some evening, weekend, or holiday hours may be needed to meet operational needs

• Because of government regulations, only U.S. persons can be considered: U.S. citizens, naturalized citizens, permanent residents, and approved asylees or refugees
• Any offer depends on passing a background check and drug screen
• Our client is an equal opportunity employer (vets/disabled)