Prototype Development Engineer

POSITION SUMMARY

As the Prototype Lab Engineer, this role is responsible for coordinating and supporting the fabrication, assembly, installation, and modification of prototypes, mockups, in accordance with engineering specifications, 3D models, drawings, and technical documentation. The position requires strong manufacturing engineering and hands-on build experience to define fabrication methods, support shop-floor execution, troubleshoot technical issues, and ensure the safe and efficient completion of prototype activities.

The role is responsible for conducting safety assessments, leading safety briefings, ensuring compliance with laboratory and job safety requirements, coordinating resources and schedules, and collaborating with engineering, manufacturing, and supporting organizations.

Acts as the engineer accountable for prototype and mockup fabrication activities, providing technical guidance, manufacturing instructions, and work direction to support safe, high-quality execution. Performs safety and skill assessments for laboratory personnel and activities, and supports Project Managers with quotations, Minimum Information Packages, schedules, technical specifications, manufacturing plans, and recommendations related to prototype development, fabrication, assembly, and testing activities.

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JOB RESPONSIBILITIES

• Serve as the primary safety representative accountable for Environmental, Health, and Safety topics within the labs, actively promoting a safety-first culture and ensuring a safe working environment for team personnel, visitors, and supporting functions.
• Ensure the prototype lab team and visitors follow company job safety policies and all regulatory requirements, including OSHA, EPA, and state and federal regulations.
• Coordinate proactive safety risk identification, mitigation planning, and follow-up actions for prototype fabrication, shop activities, test setups, tooling, equipment usage, and lab operations.
• Ensure Job Safety Analysis, risk assessments, required permits, personal protective equipment, machine guarding and safety controls are properly defined, communicated, and verified before work execution.
• Develop aircraft prototype and/or mockup interior engineering packages as well as test and validation activities based on market, product, and certification requirements in order to ensure adherence to quality as well as the overall program cost and schedule goals.
• Responsible for build and test capabilities and capacity, in line with EETC road maps and strategies
• Plan the prototype lab technicians' daily activities, including risk assessment and control measurements per company for safe operation.
• Provide long-term capacity planning forecasts for all drive unit labs, in collaboration with the program management team
• Manage and organize prototype shop and the lab fabrication areas such as metal shop, wood shop, electrical and electronic shop, etc.
• Oversee continuous improvement initiatives in all operational activities (build and test)
• Plan and purchase tools, materials, and consumables necessary for prototype lab operation.
• Perform prototype and proof-of-concept tests from the manufacture, preparation, setup, fixtures surrogates, and all addiction tool necessary.
• Manage the instrumentation calibration plan according to company-established procedures.
• Ensure project-related engineering data is in compliance with corporate policies and certification requirements
• Applies technical principles, theories, and concepts to solve a wide range of challenging prototype, mockup, and proof of concept fabrication
• Support the development projects technically during quotation, execution, and certification concerning mockups, prototypes, and proof of concepts in coordination with the project management office.

• Develop and produce different levels of mockups representation from volumetric up to high fidelity mockups for sales and commercial purposes.
• Support the aircraft production line with the fabrication of tooling, fixtures, and GSE.

ESSENTIAL KNOWLEDGE, SKILLS AND ABILITIES

Education:

• Must have a bachelor's degree in engineering or a related field or equivalent work experience

Experience:

• Prior experience in prototype and/or mockup development, fabrication, and test and validation activities is required
• A minimum of 5 years of experience in prototype and/or mockup, fabrication, and test and validation labs, ideally for aerospace.

Knowledge, Skills & Abilities:

• Demonstrated knowledge of aircraft interior prototype, manufacturing, installation, test, and validation
• Experience with trim and finish and/ or seating manufacture is a plus
• Ability to navigate ambiguity and coordinate work in a dynamic technical environment.
• Ability to identify and quickly mitigate unforeseen problems creatively and effectively.
• Strong coordination, accountability, and collaboration skills in a rapidly changing and dynamic environment - experimental mindset
• Highly motivated and team-oriented
• Systemic vision, Strong problem-solving ability, and self-starter
• Comprehension, understanding, and execution of broad practices associated with the field assigned and related fields.
• Applies these understandings in the completion of complex work assignments.
• Role requires application of advanced skills attained via greater years of experience towards solving complex issues and problems.
• Acts as Project Representative from the immediate group they are assigned to in the resolution of problems/issues encountered across multiple functions which require a coordinated response.
• Impact within their job and their department based on their work responsibilities begins to regularly extend to certain other functional groups within the organization.

• Errors could adversely impact internal and/or external customer business relationships and could result in moderate to significant work delays and/or costs to correct.
• Significant leeway is established at this level to determine the best individual approach to achieve stated objectives.
• Typically provides guidance on task completion to all Team Members and may also review and check their work assignments.
• Proficient computer skills with use of Microsoft Office applications
• Customer-focused with good relationship-building skills
• Professional appearance and demeanor
• Possess exceptional communication (both oral and written) and listening skills, with a strong orientation to detail, and the ability to make accurate, informed decisions.
• Effective time management and organizational skills; ability to become involved in a number of projects in a fast-paced work environment.
• Proven success in a fast-paced development and prototype environment and possess a willingness to take ownership, accept accountability, and thrive under pressure.

W orking Conditions / Environment/ Special Requirements:

• Authorized to work in the U.S.
• Ability to work in a safe professional manner adhering to all regulatory requirements including OSHA, EPA, State and Federal regulations.
• Employees will be subject to random drug and alcohol testing under FAA regulations
• Availability for domestic and international travel
• Ability to work flexible hours and different shifts if required
• This is an on-site position

GENERAL COMMITMENT

• Commitment to company values and compliance, with department norms, policies, directives, and procedures.
• Incorporates Lean and P3E processes and concepts into daily activities.
• Strives for continuous improvement of processes and procedures.
• Honors and protects confidential and proprietary documents and information.
• Satisfies work schedule requirements.

The job description is not designed to cover or contain a comprehensive listing of all activities, duties or responsibilities that are required by the employee. Performs other duties as assigned.

Embraer is An Equal Opportunity Employer.