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. With 11 locations across North America, our engineering expertise and operational excellence set us apart. Since 1948, we have a proven track record of delivering high-quality, reliable, safe, and efficient products and services.

About the role

With minimal supervision, the Manufacturing Engineer will collaborate with engineering, operations, quality, and project management to develop technical manufacturing solutions for new and existing aerospace programs.

Responsibilities

• Develop technical manufacturing solutions to improve processes, tooling, and equipment.
• Define manufacturing processes for sheet metal and extrusion aluminum parts.
• Develop and implement multi-step fabrication processes including heat treatment.
• 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 workforce 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 specifications and arrange for the 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 production considerations.
• Coordinate and direct process improvement teams.
• Assist with resolution of customer, technical, and quality issues.
• Coordinate teams to complete tasks.
• Collect, analyze, interpret, and present technical and business information.
• Work successfully in a team-based environment.
• Operate effectively in a high-stress and constantly changing environment.
• Travel up to 15% of the time.

Requirements

• 4-year degree in Engineering.
• Minimum 4 years of 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 and 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.
• Exposure to noise levels ranging from quiet to extremely loud.
• Required to wear Personal Protective Equipment (PPE) when working on the manufacturing floor, including eye, ear, and foot protection.
• May occasionally lift and/or move up to 50 pounds.

Pay

Annual pay range: $85,000 - $92,000

Benefits

• 401(k) retirement savings plan with a percentage company-match contribution.
• Competitive wages.
• Paid holidays and paid time off.
• Medical, dental, vision, life, and accidental insurance.
• Short-term and 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.