Senior Composite Technician

Key Responsibilities

• Lead fabrication and assembly of advanced composite structures, including complex layups, multi-material assemblies, and tight tolerance R&D and flight hardware
• Perform prepreg material handling, including identification of material condition, fiber orientation, tack, resin content, and suitability for process steps
• Assist in the development and execution of advanced vacuum bagging strategies, cure setups, and autoclave/oven cycles to ensure repeatable, high-quality laminates
• Interpret complex engineering drawings, CAD models, and manufacturing plans with minimal oversight
• Collaborate directly with engineering to refine layup schedules, troubleshoot design-for-manufacture challenges, and validate new materials and processes
• Build, maintain, and improve composite tooling, including molds, mandrels, and fixtures
• Provide input to improve manufacturing documentation, including work instructions, work order steps, and quality checkpoints
• Operate and maintain specialized composite fabrication equipment (e.g., custom ovens, precision cutters, metrology tools, and clean-room environments)
• Perform inspection of composite components (visual, tap test, dimensional, etc.) and ensure compliance with aerospace quality and safety standards
• Assist with root cause analysis and corrective actions for fabrication issues, material deviations, and process nonconformances
• Train and mentor Level I–III technicians, setting the standard for craftsmanship, precision, and shop professionalism
• Contribute to continuous improvement efforts in tooling design, layup methodology, material flow, and production efficiency

Required Qualifications

• 7-10+ years of hands-on composite fabrication experience (aerospace experience strongly preferred)
• Proficiency in prepreg layup, vacuum bagging, debulk/cure cycles, and composite assembly techniques
• Strong knowledge of composite material systems (prepreg, dry fiber, adhesives, film adhesives, core materials, etc.)
• Proven ability to independently execute complex layups and assemblies with high precision and low rework rates
• Ability to identify material type or condition through handling (e.g., frozen vs. Out-time expired prepreg, resin system distinctions)
• Ability to lead troubleshooting, mentor teams, and provide technical direction
• Strong understanding of AS9100 practices, clean-room operation, and aerospace quality standards
• Comfortable in a fast-paced, iterative R&D environment where processes evolve quickly
• U.S. Citizenship or Permanent Resident (due to government contract requirements)

Preferred Qualifications

• Experience with high-strain composites, deployable structures, or spaceflight hardware
• Familiarity with environmental testing (thermal, vibration, load testing, etc.)
• CNC machining, metrology, or precision alignment experience
• CAD experience (e.g., SolidWorks)
• Experience with First Article builds