R&T Engineer, Materials & Processing

Job Purpose

This role supports research and technology projects that help advance AEC’s composite manufacturing capabilities. You’ll be part of a team exploring new materials, new processes, and new ways to build advanced composite structures. The work includes hands-on engineering, collaborative problem solving, and contributing to projects that expand AEC’s technology portfolio. Someone in this role will grow their technical capabilities while supporting both internal initiatives and customer-focused development efforts.

Job Responsibilities

• Identify and lead initiatives to enable and sustain world class technical competency and proficiency of the Research and Development organization as needed to meet company goals.
• Identify advanced technologies and applications for potential business development.
• Stay abreast of industry trends in technology development and best practices, participate in relevant industry events.
• Contribute tactical effort to specific programs as required.
• Significant effort is expected for key strategic programs such as:
  • Identify and evaluate alternate materials for use in 3D woven/molded composite structures.
  • Identify manufacturing processes that will complement those currently in use at AEC or will expand the range of components which can be fabricated at AEC.
  • Establish plans for maturing the technologies identified.
  • Provide mentoring and technical leadership; assist in the assessment of technical competencies of the organization, identify skills and training needs and assist in developing and executing plans to address them.
  • Collaborate and lead as necessary the design verification and validation process of new products, including material and component testing.
  • Establish material characterization and qualification plans in line with certification agencies expectations (e.g., FAA, EASA).
  • Design, source, and procure equipment and tooling needed to support new composite parts and manufacturing processes.
  • Lead and/or support internally funded, customer funded, and capital expenditure projects from idea phase (project creation) through completion.
  • Must have ability to lead small working team on dedicated project.
  • Evaluate the results of computational models and experiments to assess the performance of processes, materials and structures.
  • Develop quotations, cost models, and trade studies in support of various business development activities.
  • Participate in key customer visits, program team meetings, and activities related to engineering/technical elements of various programs.

Qualifications/Characteristics

• Bachelor’s degree in materials, mechanical, civil, aerospace engineering, or a related field. Advanced degree a plus.
• 2-5 years in aerospace, composites, materials engineering, or related fields preferred.
• Exposure to composite materials, manufacturing processes, or product development.
• Exposure to Ceramic Matrix Composites (CMC) and related processing methods is a plus.
• High proficiency and demonstrated technical skills related to the design, development, and manufacturing of some or all of the following composite structures and processes:
  • Aerospace primary and secondary composite structures and related manufacturing and processing techniques (i.e. weaving, complex textile preforms, dry or prepreg layup, RTM, VARTM, press molding, autoclave and out-of-autoclave processing, bonding, finishing, assembly).
  • Exposure to software (e.g. CAD with SolidWorks or Catia, Finite Element Analysis with Abaqus, LS-Dyna, etc., RTM process modeling with PAM-RTM, LIMS, etc., Draping analysis with FiberSim, PAM-FORM, etc.).
  • Strong understanding of mechanics and strength of materials.
  • Familiarity with methods and analysis of material characterization methods and analysis (i.e. DSC, DMA, rheology, etc.), destructive testing (coupons, sample preparation, component testing), and non-destructive composite test methods (μCT scanning, Ultrasonic, laser scanning, etc.).
  • Familiarity with new product introduction (NPI) standards, aerospace certification methods, and the development of design allowables.
  • Team and people skills, including interpersonal skills that are required to lead, mentor, communicate, and build the technical capabilities of the organization.
  • MSOffice proficient; Excellent written and oral communication.
  • Proven problem-solving skills in teamwork setting.
  • Proven willingness and ability to learn.
  • Willingness to perform “hands-on” work in a dynamic setting.
  • Action Oriented; Results Driven; Strong Decision-making and Customer Focus.

Working Conditions

Indoor office/manufacturing environment, duties performed indoors, adequate lighting and comfortable temperatures. Occasional exposure to moderate noise and machinery with mechanical moving parts. Ability to work 24/7 schedule and be available as business situations required. Occasional travel may be required.

Physical Requirements

Occasionally positions self to move an office item >10 lbs. Frequently move about the production floor and office area to attend meetings or trainings. Must be able to remain in a stationary position up to 75% of the time. Frequently operates on a computer.