Manufacturing Engineer - Forming

Manufacturing Engineer

Sonaca North America is driven by a passion for innovation and a commitment to excellence. As a leading provider of aerospace and defense solutions, we are dedicated to making air and space travel safe and sustainable. We have 11 locations across North America and our engineering expertise and operational excellence set us apart from the competition.

Since the beginning in 1948, we have a proven track record of delivering high-quality products and services that are reliable, safe, and efficient. Our team of experts is dedicated to staying ahead of the curve in the aerospace and defense industry, utilizing the latest technologies and processes to ensure that we deliver the best possible solutions to our customers.

Position Summary

We are currently seeking a Manufacturing Engineer. With minimal supervision, the Manufacturing Engineer will work with engineering, operations, quality, and project management to develop technical manufacturing solutions for new and existing programs.

Essential Job Responsibilities

• Develop technical manufacturing solutions to improve processes, tooling and equipment.
• Define manufacturing process for Sheet metal and Extrusion Aluminum parts
• Develop and implement multi-step process of forming Fabrication including Heat treatment.
• Perform research to design and develop manufacturing processes utilizing Swing Arm (V-Press), End Pull (Longitudinal), and Side Pull (Transverse) stretch forming presses based on component geometry and material type.
• Conduct in-depth process monitoring (e.g., tonnage, elongation, strain mapping) to achieve optimal material properties and minimize defects.
• Review product specifications, drawings, and Bills of Material (BOMs) for optimal manufacturability and cost-effective fabrication using the appropriate forming press type.
• Lead new product introduction (NPI) activities, focusing on forming fabrication processes from prototype to full-rate production.
• Analyze and plan work force utilization, space requirements, workflow, and layout.
• Provide input to estimate project costs, tooling and return on investment (ROI).
• Work with engineering, operations and project management concerning tool design.
• Consult with vendors to determine product specification sand arrange for purchase of industrial products.
• Perform product/process analysis for cost reduction, quality improvement and efficiency.
• Work with management, engineering, estimating, and other staff regarding manufacturing capabilities, production schedules and other considerations regarding production processes.
• Coordinate and direct process improvement teams.
• Assist with resolution of customer, technical and quality issues.

• Ability to coordinate teams to complete tasks.
• Ability to collect, analyze, interpret and present technical and business information.
• Ability to successfully work in a team-based environment.
• Willingness to work in a high stress and constantly changing environment.
• Excellent oral and written communication skills.

Travel Required

Yes, 15% of Time Traveling

Education and Experiences

• Requires 4-year degree in Engineering.
• 4 years minimum years related experience.
• Aerospace industry knowledge is preferred.
• Working knowledge of 3D CAD systems required. CATIA v5 is preferred.
• Experience in sheet metal fabrication is desired.
• Assembly engineering experience is desired.
• Knowledge of Control Systems.
• Knowledge of hydraulic systems.
• Deep knowledge of stretch forming principles, material behavior (elasticity, plasticity), and advanced compensation techniques for spring-back in high-strength aluminum alloys.

Physical Requirements

• Ability to sit or stand for extended periods of time
• Noise levels ranging from quiet to extremely loud
• Required to wear Personal Protective Equipment (PPE) when working on the manufacturing floor including, but not limited to, eye, ear, and foot protection
• May occasionally lift and /or move up to 50 pounds

Annual Pay Range - $85,000 - $92,000

Why Choose Sonaca North America?

We take care of our people.

• 401(k) retirement savings plan with a percentage company-match contribution
• Competitive wages
• Paid holidays
• Paid time off
• Medical, dental, vision, life, and accidental insurance
• Short-term disability
• Long-term disability
• Employee assistance plan — for access to counseling, consulting, and other community resources
• Wellness program
• Tuition assistance
• Subject to eligibility, terms, and conditions