Director/Senior Manager of Research & Development -- Friction Stir Welding (FSW)

Job Description

Job Description

Description:

Ascentec Engineering is seeking a highly experienced Director or Senior Manager of Research & Development – Friction Stir Welding (FSW) to lead the expansion of the company's advanced joining technology capabilities and establish Ascentec as a premier development and manufacturing partner for aerospace, defense, space, and military applications.

This role will be responsible for developing and executing the company's FSW technology roadmap, advancing process capabilities, leading customer-funded and internally funded R&D programs, and creating differentiated manufacturing solutions that support growth in defense markets, including missile systems, munitions, launch systems, hypersonics, aerospace structures, naval systems, next-generation defense platforms, and nuclear plant welding applications.

The successful candidate will combine deep technical expertise in friction stir welding and solid-state joining technologies with strong leadership, customer engagement, and commercialization experience. This position will play a key role in transforming Ascentec's FSW capability from a manufacturing process into a strategic growth platform.

This position is onsite (not remote, not hybrid) with a travel expectation of 10%. This position is not eligible for Visa sponsorship or transfer of Visa sponsorship.

Requirements:

Technology Strategy & Innovation:

• Develop and execute a multi-year FSW technology roadmap aligned with corporate growth objectives.
• All welding and joining technologies – including e-beam welding, mig and tig welding, robotic/manual welding, diffusion bonding, vacuum brazing, rotary welding, orbital welding, etc.
• Identify emerging technologies and applications that can create competitive advantages.
• Lead development of advanced FSW processes for:
• Aluminum alloys
• Copper alloys
• Dissimilar material joining
• High-strength aerospace materials
• Thick-section structural components
• Evaluate and implement adjacent technologies including:
• Friction stir processing
• Refill friction stir spot welding
• Friction stir additive manufacturing
• Hybrid manufacturing processes
• Automation and robotic FSW systems

Research & Development Leadership:

• Lead internal and customer-funded R&D initiatives.
• Establish and manage FSW development laboratories and testing capabilities.
• Direct process qualification and validation efforts.
• Develop experimental plans, process characterization methodologies, and statistical process controls.
• Lead Design of Experiments (DOE) programs to optimize process performance.
• Manage technology maturation from concept through production implementation.

Defense & Government Programs

• Identify and pursue government-funded R&D opportunities.
• Support proposal development for:
• Department of Defense
• U.S. Army
• U.S. Navy
• U.S. Air Force
• Missile Defense Agency
• DARPA
• NASA
• Department of Energy
• Build relationships with government laboratories and defense innovation organizations.
• Represent Ascentec in technical reviews and customer engagements.

Product & Process Development

• Develop new FSW applications for defense and aerospace customers.
• Establish qualification methodologies and acceptance criteria.
• Drive development of proprietary tooling, fixtures, and process technologies.
• Work with engineering teams to transition R&D projects into production.
• Support customer qualification and first article programs.

Customer Engagement

• Serve as the technical face of Ascentec's FSW capabilities.
• Engage directly with customer engineering organizations.
• Support business development efforts through technical presentations and demonstrations.
• Participate in industry conferences and technical forums.
• Publish technical papers and represent Ascentec in industry working groups where appropriate.

Team Leadership

• Build and lead a high-performance FSW R&D organization.
• Recruit, mentor, and develop engineers and technical specialists.
• Establish laboratory safety and engineering standards.
• Manage budgets, capital investments, and resource planning.
• Collaborate with manufacturing, quality, operations, and business development teams.

Required Qualifications:

Education

• Bachelor's degree in:
• Manufacturing Engineering
• Materials Science
• Mechanical Engineering
• Metallurgical Engineering
• Aerospace Engineering

Required:

• Master's degree required for the senior level role.
• PhD in a related engineering discipline required for the director level role.

Required Experience:

Director Level:

• 12+ years of engineering and technology development experience.
• 8+ years working directly with friction stir welding technologies.
• Experience leading R&D organizations or advanced manufacturing technology groups.
• Proven history developing new manufacturing technologies from concept through commercialization.
• Experience supporting defense, aerospace, or space programs.

Senior Manager Level:

• 8+ years of engineering experience.
• 5+ years of direct FSW process development experience.
• Experience managing technical teams and customer development programs.
• Demonstrated success leading advanced manufacturing projects.

Technical Requirements:

Strong knowledge of:

• Friction Stir Welding process fundamentals
• All joining technologies
• Metallurgy and materials science
• Aerospace and defense materials
• Process qualification methodologies
• Weld characterization and testing
• Nondestructive evaluation techniques
• Design of Experiments (DOE)
• Statistical analysis and process control
• Manufacturing automation
• Finite Element Analysis (FEA) concepts
• Product development lifecycle management

Preferred Qualifications:

Experience with:

• Missile and munitions manufacturing
• Rocket motor hardware
• Aerospace structures
• Cryogenic tanks and pressure vessels
• Space launch systems
• Hypersonic vehicle components
• Naval systems
• Defense manufacturing environments

Knowledge of:

• AWS standards
• ASME standards
• AS9100
• NADCAP
• ITAR
• DFARS
• Government R&D contracting

Compensation:

Senior Manager, FSW R&D:

• Salary Starts at $145,000 per year and may be higher based on experience, skills, and qualifications
• Annual Discretionary Commission, based on performance metrics: Commission earnings of 15%+ of base salary, with additional upside based on performance

Director, FSW R&D:

• Salary Starts at $160,000 per year and may be higher based on experience, skills, and qualifications
• Annual Discretionary Commission, based on performance metrics: Commission earnings of 20%+ of base salary, with additional upside based on performance

Benefits:

• Dental and Medical w/vision coverage insurance plans offered
• STD/LTD & Life insurance plans offered
• FSA and DCA available
• PTO and Holiday pay
• Immediate 100% vesting Safe Harbor 401(k) retirement saving plan with matching contributions
• Educational aid program available
• Purchase discounts, membership discounts, and many other incentives

Applicant must be able to pass a drug screen and criminal background check prior to employment.

ITAR REQUIREMENTS: To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Ascentec Engineering is an Equal Opportunity Employer; employment with Ascentec Engineering is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.