Quality Inspector IV (NDT)

Senior Quality Inspector

Firefly Aerospace is seeking an experienced Senior Quality Inspector with welding inspection expertise to join our inspection team. This role serves as an embedded shop inspector, ensuring the quality and integrity of fabricated and welded hardware throughout the manufacturing process. The ideal candidate will be a Certified Welding Inspector (CWI) with multiple NDT certifications who can generate and manage quality documentation, coordinate inspection services, communicate with engineers, technicians, and welders, and support the many unique demands for the custom hardware designed and built by the Firefly GSE Team.

Key Responsibilities:

Welding & Fabrication Inspection:

• Inspect weldments for dimensional accuracy and quality requirements throughout the weld/fabrication process
• Perform in-process and final inspections of welded assemblies, pressure vessels, structural components, and fabricated hardware
• Verify welder qualifications and welding procedure specifications (WPS) compliance
• Monitor weld quality and adherence to approved welding procedures
• Conduct pre-weld, in-process, and post-weld inspections per applicable codes and standards
• Review and approve weld travelers and production documentation

Non-Destructive Testing (NDT):

• Perform NDT inspections using multiple methods:
• Magnetic Particle Testing (MT)
• Radiographic Testing (RT)
• Visual Testing (VT)
• Liquid Penetrant Testing (PT)
• Interpret NDT results and make accept/reject decisions based on applicable codes and acceptance criteria
• Prepare detailed NDT inspection reports documenting findings and disposition
• Ensure proper NDT technique selection for various materials, geometries, and weld types

Quality Documentation Management:

• Create and maintain weld maps showing weld locations, numbers, and inspection status
• Generate comprehensive NDT inspection reports for all tested components
• Document and certify hydroproof/hydrostatic test results and reports
• Collect, review, and maintain Material Test Reports (MTRs) and Certificates of Compliance (C of C)
• Manage traceability documentation for materials, welders, and inspection activities
• Prepare inspection data packages for customer deliverables and project closeout
• Maintain accurate records in quality management systems

Inspection Coordination & Facilitation:

• Identify requirements for specialized inspection services (internal or external)
• Coordinate and schedule external inspection services including:
• Radiographic Testing (RT) from external vendors
• Laser tracking and dimensional verification services
• Coordinate Measuring Machine (CMM) inspection services
• Other specialized NDT or metrology services
• Interface with third-party inspection agencies and vendors
• Review and approve external inspection reports for completeness and accuracy
• Manage inspection service vendor relationships and performance

Receiving Quality Inspection:

• Perform receiving quality inspections for incoming GSE purchases
• Verify dimensional accuracy, workmanship quality, and conformance to purchase order specifications
• Inspect purchased components including:
• Structural steel and welded assemblies
• Hardware, fittings, and off-the-shelf components
• Umbilical systems and cable assemblies
• Electrical control panels and instrumentation
• Pressure vessels and fluid systems
• Review supplier-provided documentation (MTRs, C of Cs, test reports, certifications)
• Generate nonconformance reports (NCRs) for rejected or discrepant materials
• Maintain receiving inspection records and supplier quality metrics

Standards & Compliance:

• Ensure compliance with AS9100D quality management system requirements
• Apply AWS D1.1 (Structural Welding Code - Steel), AWS D1.2 (Aluminum), and other applicable welding codes
• Follow ASME Section VIII (Pressure Vessels) and Section IX (Welding Qualifications) as applicable
• Apply NASA standards (NASA-STD-5005, NASA-STD-5009) for GSE design verification
• Verify conformance to engineering drawings, specifications, and work instructions
• Support contamination control requirements for flight-critical interfaces

Collaboration & Support:

• Work closely with fabrication, welding, engineering, and GSE operations teams
• Collaborate with Manufacturing Engineers and GSE Leadership to improve fabrication processes and product quality
• Communicate inspection findings and quality concerns clearly and promptly
• Participate in root cause analysis and corrective action activities for weld-related defects
• Support continuous improvement initiatives and lessons learned
• Provide technical guidance to welders and fabricators on quality requirements
• Assist with supplier quality audits and assessments

Required Qualifications:

• High School Diploma or GED; Associate's degree in Welding Technology, Quality Assurance, or related field preferred
• Certified Welding Inspector (CWI) certification from AWS (American Welding Society) - Required
• Level 2 or Level 3 NDT certifications (per NAS 410 or SNT-TC-1A) in the following methods:
• Magnetic Particle Testing (MT) - Required
• Radiographic Testing (RT) - Required
• Visual Testing (VT) - Required
• Liquid Penetrant Testing (PT) - Required
• Minimum 5 years of quality inspection experience in welding, fabrication, or aerospace manufacturing
• Strong knowledge of welding codes and standards (AWS D1.1, AWS D1.2, ASME Section VIII & IX)
• Ability to read and interpret complex engineering drawings, weld symbols, and technical specifications
• Proficiency with precision measurement instruments and welding inspection gauges
• Strong understanding of GD&T (Geometric Dimensioning and Tolerancing)
• Working knowledge of AS9100 quality management systems
• Experience with pressure vessel inspection and hydrostatic testing
• Excellent attention to detail and ability to identify weld defects and discontinuities
• Strong written and verbal communication skills for technical reports and coordination
• Proficiency with Microsoft Office (Word, Excel) and quality management software
• Ability to make independent accept/reject decisions based on code requirements
• U.S. Person status required (U.S. Citizen, Lawful Permanent Resident, Refugee, or Asylee) due to ITAR/EAR requirements

Preferred Qualifications:

• Associate's or Bachelor's degree in Welding Engineering, Manufacturing Engineering, or related technical field
• Experience with AS9102 First Article Inspection (FAI) procedures
• Familiarity with NASA standards for ground support equipment (NASA-STD-5005, NASA-STD-5009)
• Experience inspecting aerospace pressure vessels, fluid systems, and structural weldments
• Knowledge of aerospace electrical standards (IPC-A-610, IPC/WHMA-A-620)
• Experience with stainless steel, aluminum, titanium, and exotic alloy welding inspection
• Experience with orbital welding and automated welding systems
• Proficiency with quality management software (e.g., ETQ, TrackWise, SAP QM)
• Experience coordinating laser tracking, CMM inspection, and advanced metrology services
• Previous experience in launch vehicle or spacecraft GSE manufacturing
• Knowledge of cryogenic systems and pressure testing procedures
• Experience managing vendor quality relationships and external inspection services
• Understanding of functional safety standards (IEC 61508, MIL-STD requirements)