SUMMARY The Automated Fiber Placement (AFP) Engineer is responsible for the development, and optimization of automated composite layup processes and overseeing the AFP programming process using Ingersoll AFP systems. This role supports production and engineering by generating precise ply programs, improving part quality, reducing cycle time, and troubleshooting AFP-related issues in the manufacture of complex aerospace components. The AFP Engineer works closely with design engineering, NC programming, operations, quality, and maintenance teams.
The following essential job functions are performed as an Automated Fiber Placement Engineer:
RESPONSIBILITIES - Oversee the development AFP ply programs for composite parts using Ingersoll Gen2, (VCP) Vericut Composite Programming, and (VCS) Vericut Composite Simulation programming tools and simulation software, ensuring conformance to design intent and manufacturing constraints
- Translate engineering models, ply books, and lamination schedules into executable AFP paths with accurate fiber orientation, coverage, and boundaries
- Support Ingersoll machine setup, calibration, and laser alignment for first article and repeatable production runs
- Analyze and optimize machine pathing to minimize defects (e.g., gaps, overlaps, tow steering errors), improve machine efficiency, and extend tool life
- Review and validate AFP programs with simulations and dry runs, working alongside operators during production start-ups
- Collaborate with design engineering to provide design for manufacturability (DFM) feedback for composite parts intended for AFP
- Investigate and resolve machine and process-related issues, working cross-functionally with maintenance and Ingersoll technical support as needed
- Participate in tooling design reviews to ensure compatibility with AFP head dimensions, access, and laser projection systems
- Implement and document process improvements, material usage reductions, and automation enhancements
- Work with facilities team to enhance critical spares documentation and write PM plans.
- Develop and maintain standard work instructions, AFP best practices, and process documentation
- Support audits, root cause investigations, and corrective actions involving AFP-manufactured parts
- Maintains composure under pressure while successfully managing multiple deadlines
- Being at work on time and maintaining good attendance is a condition of employment and is an essential function of the job
- Must have excellent communication skills, both verbal and written in the English language
QUALIFICATIONS Required - Bachelor's degree in Mechanical Engineering or a related Engineering field.
- 5 years experience in carbon fiber composite aerospace manufacturing
- Strong technical aptitude and ability to quickly become an expert on complex hardware.
- Automated Fiber Placement experience
- Experience with interrogating machine efficiency and implementing process improvements to reduce time and waste.
- Proficiency in CAD software and AFP Programming.
- Excellent communication skills and ability to collaborate effectively with cross-functional teams.
- Demonstrated track record of driving process improvements and delivering results in a fast-paced environment.
- High level of initiative, self-motivation, and ability to thrive in a dynamic and challenging work environment.
- Excellent problem-solving and analytical abilities.
Desired - 5+ years working in a aerospace manufacturing or engineering environment with a bachelor's degree in mechanical, aerospace, or similar area.
- Experience with capital equipment implementation.
- Master's degree is a plus.
- Six Sigma or Lean manufacturing Black Belt certification
Firefly offers outstanding benefits for our employees, including generous health, dental and vision plans with low plan deductibles, parental leave, educational/relocation reimbursement, short term disability, and flexible PTO options. 
