Sr Materials & Process Engineer

U.S. citizenship is required, as only U.S. citizens are authorized to access information under this program/contract.

About the role

We are seeking a highly skilled and motivated Sr. Materials & Process Engineer to provide technical leadership for material selection, qualification, and process integration across the manufacturing site. Operating in a fast-paced environment, this role is responsible for driving innovation in materials characterization and analysis in support of key initiatives that improve critical performance metrics. Join our team at Collins Aerospace in Wilson, NC—a global leader dedicated to saving lives through the design and manufacturing of fire protection systems for commercial and military aircraft and ground vehicles.

Responsibilities

• Provide technical leadership for surface finishing (paint, coatings, sealants), chemical processing (cleaning, pickling, passivation, chromate, etc.), and bonding processes, including surface preparation, masking, application, curing, and sealing; establish and maintain critical process parameters, controls, acceptance criteria, and monitoring methods.
• Support troubleshooting of issues involving adhesion, coating thickness, cure, contamination, surface preparation, bond strength, defects, appearance, and environmental conditions.
• Partner with Manufacturing Engineering, Quality Engineering, Operations, and Design Engineering to investigate nonconformances, escapes, and process variation, performing root-cause analysis and implementing corrective actions.
• Develop, optimize, qualify, and standardize processes to improve yield, quality, throughput, material utilization, and cost.
• Lead continuous improvement initiatives to reduce scrap, rework, and process variation.
• Develop and maintain process specifications, work instructions, process controls, and manufacturing best practices.
• Support qualification of new materials, suppliers, application methods, equipment, and processes.
• Lead root-cause analysis and corrective actions for process-related defects and nonconformances.
• Support new product introduction, process validation, PFMEA, control plans, and production readiness.
• Ensure processes comply with applicable customer, regulatory, environmental, safety, and industry requirements.

Requirements

• Typically requires a degree in Engineering, Materials Science, or Chemistry and minimum 5 years of prior relevant experience or an Advanced Degree in a related field and minimum 3 years of experience.
• Direct experience with chemical processing operations, such as cleaning, pickling, passivation, chromate, anodizing, or related chemical surface treatments.
• Direct experience with surface finishing processes such as paint, coatings, sealants, masking, surface preparation, or curing.
• Direct experience with chemical processing, adhesive bonding, or sealant processes.
• Direct experience with material characterization methods such as SEM, EDS, CT scan, fatigue testing, or corrosion analysis.

Qualifications

Preferred:

• Aerospace, defense, or highly regulated manufacturing environment.
• AS9100, Nadcap, FAA, or other aerospace quality and regulatory requirements.
• Experience in a production support environment.
• Understanding of lean manufacturing, Six Sigma, or other process improvement methodologies.
• Experience with DOE, SPC, statistical analysis, or other advanced process control techniques.

Benefits

• Medical, dental, and vision insurance.
• Three weeks of vacation for newly hired employees.
• Generous 401(k) plan that includes employer matching funds and separate employer retirement contribution, including a Lifetime Income Strategy option.
• Tuition reimbursement program.
• Student Loan Repayment Program.
• Life insurance and disability coverage.
• Optional coverages: pet insurance, home and auto insurance, additional life and accident insurance, critical illness insurance, group legal, ID theft protection.
• Birth, adoption, and parental leave benefits.
• Ovia Health, fertility, and family planning.
• Adoption Assistance.
• Autism Benefit.
• Employee Assistance Plan, including up to 10 free counseling sessions.
• Healthy You Incentives, wellness rewards program.
• Doctor on Demand, virtual doctor visits.
• Bright Horizons, child and elder care services.
• Teladoc Medical Experts, second opinion program.

May be eligible for relocation.

Pay

The salary range for this role is 86,800 USD - 165,200 USD. The salary range provided is a good faith estimate representative of all experience levels. RTX considers several factors when extending an offer, including but not limited to, the role, function and associated responsibilities, a candidate’s work experience, location, education/training, and key skills.

Schedule

This is an onsite role. Employees in onsite roles will work primarily onsite, including all production and maintenance employees, as they are essential to the development of our products.