Composite Manufacturing Engineer

GSE Dynamics Inc. is a full-service engineering and manufacturing company located in Hauppauge, NY seeking an experienced Composite Manufacturing Engineer with a strong background in composite materials, production processes and Department of Defense program requirements to join our team.

Responsibilities:

• Develop, optimize, and maintain manufacturing processes for composite structural components and assemblies, including hand layup, resin infusion, RTM, autoclave curing, and out-of-autoclave processes.

• Design, develop, and validate composite tooling, fixtures, templates, and assembly aids to support efficient manufacturing.

• Create and maintain manufacturing plans, work instructions, routers, process specifications, and standard operating procedures in accordance with customer, DoD, and company requirements.

• Develop and qualify composite materials, manufacturing processes, and tooling in compliance with MIL-STDs, aerospace OEM specifications, and program requirements.

• Develop layup, bonding, trimming, machining, drilling, curing, and assembly processes for composite structures.

• Evaluate engineering drawings, CAD models, and technical specifications to ensure manufacturability and support Design for Manufacturing (DFM) and Design for Assembly (DFA) initiatives.

• Collaborate with Engineering, Quality, Manufacturing, Program Management, suppliers, and customers to support product development, production readiness, and process improvements.

• Lead root cause investigations and implement corrective actions for manufacturing issues, quality concerns, discrepancies, and nonconforming material.

• Support Material Review Board (MRB), First Article Inspection (FAI), process qualification, production readiness, and Engineering Change Order (ECO) implementation activities.

• Lead continuous improvement initiatives focused on safety, quality, cost reduction, manufacturability, and production efficiency.

• Support customer audits, regulatory compliance, and quality management system requirements, including AS9100, ITAR, EAR, and other applicable aerospace and defense regulations.

Required Qualifications:

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Engineering, or a related field.

• Minimum of five (5) years of manufacturing engineering experience supporting composite materials in the aerospace or defense industry.

• Strong knowledge of composite manufacturing processes, including prepreg processing, hand layup, vacuum bagging, resin infusion, autoclave curing, out-of-autoclave curing, adhesive bonding, trimming, machining, and composite assembly.

• Experience using CAD software such as Siemens NX, CATIA, SolidWorks, or similar.

• Ability to interpret engineering drawings, GD&T (ASME Y14.5), MIL-SPECs, technical specifications, process standards, and ply books.

• Experience with manufacturing process development, tooling design, process validation, and production documentation.

• Knowledge of quality engineering principles, including FMEA, Statistical Process Control (SPC), root cause analysis, corrective actions, and failure analysis.

• Strong analytical, technical problem-solving, communication, and project management skills.

• Experience working in cross-functional engineering and manufacturing teams.

Preferred Qualifications:

• Experience supporting U.S. Department of Defense (DoD), military aerospace, or defense prime contractor programs.

• Experience supporting low-rate initial production (LRIP) and/or full-rate production environments.

• Experience with aerospace customer specifications such as Boeing BAC, Airbus AIPS, Lockheed Martin, Northrop Grumman, RTX (Raytheon), or similar.

• Knowledge of AS9100 Quality Management Systems, NADCAP special processes, and AS9102 First Article Inspection (FAI).

• Experience with Manufacturing Readiness Levels (MRLs), configuration management, and Engineering Change Orders (ECOs).

Requirements:

• U.S. Citizenship required.

• Ability to meet ITAR/EAR requirements for handling controlled technical information.

• Ability to read, write, and communicate effectively in English.

• Ability to work in a defense manufacturing environment and comply with applicable security, export control, and company policies.

Job Type: Full-time, Onsite

FLSA Classification: Exempt

Salary Range: $100,000 – $140,000 annual salary

This is an estimated salary range with any actual compensation offers to be dependent upon factors including experience, skill set, qualifications, and other factors allowed by law.

Benefits include:

• Paid Time Off

• Medical Insurance

• Flexible Spending Account

• Dental Benefit

• Life Insurance

• Aflac Supplemental Insurance

• 401k with company match

EOE/Vet/Disability

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