Senior Staff Manufacturing Engineer

About the role

Work on Archer’s most challenging composite structures, providing manufacturing input (processing technique, tooling methods, splicing guidelines, etc.) to help solve recurring issues. Mentor and guide manufacturing engineers and technicians at all levels, setting best practices, championing innovative problem-solving, and fostering a hands-on culture of ownership and accountability. Serve as the primary subject matter expert on the shop floor, leading root-cause analysis and implementing timely corrective actions. Collaborate closely with the design team to provide manufacturing input during initial design stages. Develop composite processing techniques utilizing new approaches, materials, and tooling methods. Drive tooling strategies and fixture development for prototype builds, balancing high precision with practical solutions suited to rapidly evolving programs. Export flat patterns and laser projection files from Fibersim and troubleshoot any issues seen on the shop floor with files.

Requirements

• 10+ years in aerospace manufacturing, with a focus on airframe assembly and composite structures; prototype or experimental aircraft experience strongly preferred.
• Bachelor’s or advanced degree in Aerospace, Mechanical, or Manufacturing Engineering (or equivalent experience).
• Hands-on experience with composites materials, exhibiting strong fabrication skills and assembly intuition.
• Proven track record of driving DFM (Design for Manufacturing) principles for complex composite parts (layup, bonding, cure).
• Understanding of composite part design, material properties, allowables, and testing.
• Proficiency in 3D CAD Software (NX preferred).
• Experience using Fibersim or Composite Workbench.
• Demonstrated exposure to prototype environments with ability to problem-solve.

Bonus Qualifications

• Hands-on experience with composites demonstrated through past work experience, personal projects, or student teams.
• Ability to operate composites-related equipment: autoclaves, laser projectors, ply cutters, laser trackers.
• Experience with various composite inspection techniques, M&P (Materials & Processes) standards, and test equipment.
• Passion for aviation and eVTOLs (electric Vertical Takeoff and Landing aircraft).

Pay

For this position, the targeted base pay range is $154,200 - $215,800. Actual compensation offered will be determined by job-related knowledge, skills, and experience.