Materials And Process Engineer

We are seeking an experienced Materials & Process, Materials Science Engineer to support sustaining efforts and updates for Legacy programs, and related activities for future projects, including our new cabin interior program. A successful candidate will have extensive expertise in aerospace materials, manufacturing processes, regulatory compliance, and certification processes to ensure all materials meet stringent safety, performance, and regulatory requirements common to high performance jet powered aircraft.

Key Responsibilities:

• Assess current airframe materials for obsolescence, cost reduction opportunities, and performance improvements.
• Conduct comparative analysis of existing vs. alternative manufacturing processes. Assess impact on critical performance parameters such as strength, durability, fatigue life, etc.
• Risk assessments and mitigation strategies.
• Develop and/or maintain manufacturing and engineering processes such as machining, forming, welding, heat treatment, chemical milling, and composite fabrication.
• Create and/or maintain detailed process specifications, work instructions, and quality control procedures to ensure consistent production.
• Investigate material failures and quality issues using root cause analysis methodologies. Implement corrective and preventive actions to improve product and process reliability.
• Collaborate with design engineering teams to ensure the integrity and manufacturability of designs while optimizing material usage, weight and production costs.
• Provide materials expertise during design reviews and support design changes to improve manufacturing efficiency.
• Maintain comprehensive documentation for materials specifications, testing, process controls to support FAA certification efforts.
• Maintain current knowledge of evolving regulations and industry standards affecting aircraft materials.
• Manage materials databases and FEA packages for material analysis and statistical analysis.
• Drive lean manufacturing principles and cost reduction methodologies.

Qualifications:

• Education: Bachelor’s or master’s degree in mechanical engineering, Materials Science and Engineering, Aerospace Engineering, or a related field.
• Experience:
• Minimum of 7 years of experience in the aerospace industry.
• Knowledge of material properties and testing methodologies for aerospace materials including metallic alloys, composites, polymers, coatings.
• Experience with corrosion testing and evaluation such as stress corrosion, galvanic compatibility, intergranular, etc.
• Experience with corrosion prevention methods.
• Experience performing environmental testing such as UV exposure, thermal cycling, humidity resistance, and chemical compatibility.
• Experience supporting or leading design allowable projects.
• Demonstrate strong interpersonal skills with ability to support multiple projects simultaneously, while providing stakeholders with essential expertise and risk information.
• Previous experience working with FAA DERs and certification authorities.

Preferred Experience:

• Broad exposure to aircraft development such as primary structure, systems, interiors, etc. related to high performance jet powered aircraft.
• Additive manufacturing experience.
• Experience with CATIA V5, Siemens NX, Teamcenter PLM.
• Experience with agile development sprints (Jira) and project documentation in Confluence.
• Analytical Skills: Excellent problem-solving skills with the ability to analyze complex technical data and provide effective solutions.
• Communication: Strong verbal and written communication skills, with the ability to effectively present and document technical information to various stakeholders.
• Team Player: Ability to work collaboratively in a team environment, demonstrating strong interpersonal skills.

Preferred Qualifications:

• Knowledge of honeycomb sandwich panel construction methods and best practices.
• Knowledge of honeycomb panel joining methods such as bonded joints, panel pins, inserts, etc.
• Strong understanding of mechanical fastening principles and best practices in an aerospace/aviation setting.
• Strong understanding of manufacturing processes and principles in an aerospace/aviation setting.
• Experience using testing equipment such as load frames, burn cabinets, environmental chambers, etc.