Thermal Spray Engineer

Position Summary

We are seeking a Thermal Spray Engineer to develop, support, and optimize Air Plasma Spray (APS) and thermal spray coating processes used on aerospace and industrial gas turbine components. This is a hands-on manufacturing engineering role focused on process development, robotic coating programs, troubleshooting, equipment improvements, new product introduction, and continuous improvement.

Responsibilities

• Develop, qualify, and optimize APS / thermal spray coating processes.
• Create and improve robotic spray programs, tooling, fixtures, and process parameters.
• Support FANUC robotic coating systems and equipment upgrades.
• Troubleshoot coating and manufacturing issues and implement sustainable corrective actions.
• Support new product introduction, process qualification, and production readiness.
• Improve process capability, quality, yield, throughput, and cost.
• Work with Manufacturing, Quality, Materials, Design, and Operations teams on turbine component repairs and production processes.
• Develop technical procedures, specifications, reports, and work instructions.
• Support dimensional inspection using CMM, laser/white-light scanning, gauges, and related measurement equipment.

Qualifications

• Bachelor's degree in Mechanical, Aerospace, Materials, Metallurgical Engineering, or related engineering discipline.
• 2+ years of manufacturing, process, aerospace, or gas turbine engineering experience.
• Experience with coating technologies; thermal spray or Air Plasma Spray experience strongly preferred.
• Ability to read and interpret engineering drawings, specifications, and technical requirements.
• Experience supporting manufacturing process development and troubleshooting.
• Preferred: Air Plasma Spray (APS), HVOF, or other thermal spray experience.
• FANUC robotic programming and optimization.
• Aerospace or industrial gas turbine component manufacturing/repair experience.
• Metallurgical laboratory and coating evaluation experience.
• CMM, laser scanning, white-light scanning, or other dimensional inspection methods.
• 3D CAD and/or FEA experience.
• Lean manufacturing and continuous improvement experience.
• Familiarity with FAA PMA and RS-DER requirements.