Bachelor's degree in Mechanical Engineering or related field
5 years of experience in carbon fiber composite aerospace manufacturing
Strong technical aptitude for complex hardware
Experience with Automated Fiber Placement
Proficiency in CAD software and AFP programming
Excellent communication and collaboration skills
Demonstrated ability to drive process improvements in fast-paced environments
Responsibilities
Oversee development of AFP ply programs using Ingersoll systems
Translate engineering models into executable AFP paths
Support machine setup, calibration, and alignment for production
Analyze machine pathing to minimize defects and improve efficiency
Review and validate AFP programs with simulations and dry runs
Collaborate with design engineering for manufacturability feedback
Investigate and resolve machine and process-related issues
Benefits
Generous health, dental, and vision plans with low deductibles
Parental leave
Educational and relocation reimbursement
Short-term disability
Flexible PTO options
Full Job Description
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.
To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.
About Firefly Space Systems
Firefly Space Systems was an American aerospace manufacturer based in Cedar Park, Texas. The company was founded in 2013 with the goal of developing low-cost launch vehicles for the small satellite industry. Firefly's Alpha rocket was designed to carry payloads of up to 1,000 kg to low Earth orbit. The company was acquired by EOS Launcher in 2017 and is now known as Firefly Aerospace. Firefly Aerospace is continuing the development of the Alpha rocket and is also working on a larger rocket called Beta, which is designed to carry payloads of up to 8,000 kg to low Earth orbit. Firefly Aerospace is committed to providing affordable access to space for small satellite operators.
