Position Overview:We are seeking a highy motivated and experienced Carbon Fiber Composites Design & Process Development Engineer to lead the design, analysis, and manufacturing process improvements of carbon fiber composite and parts and vessels. In this role, you will drive both research and high-volume production initiatives, bridging the gap between innovative concept development and efficient manufacturing for advanced composite systems.
Key Responsibilities:- Design and develop carbon fiber composite parts and vessels, ensuring optimal strength-to-weight rations and durability.
- Perform mechanics of materials and structural analysis of composite systems using ANSYS or other advanced simulation tools.
- Experience in translating layup design into bulk anisotropic composite property estimates.
- Develop, validate, and optimize composite manufacturing processes - from tooling and fixture design to layup, curing, and machining - to meet rigorous quality and throughput goals.
- Lead R&D initiatives as well as high-volume production efforts, seamlessly transitioning concepts to production-scale applications.
- Collaborate with cross-functional teams including design, materials science, quality, and production to select composite systems and validate performance.
- Create detailed work instructions, process documentation, and quality protocols that ensure consistency and adherence to industry standards.
- Identify opportunities for continuous improvement, applying lean manufacturing and statistical process control methodologies.
- Mentor junior engineers and technicians, and provide technical leadership during process troubleshooting and corrective action implementation.
Required Qualifications:- Education: Bachelor's degree (BS) in Materials Science, Mechanical Engineering, or a related field with a minimum of 10 years' experience, or a Master's degree (MS) or higher with at least 5 years' relevant experience.
- Demonstrated expertise in carbon fiber composite design and the mechanics of composite materials.
- Proven experience in structural analysis, particularly with simulation tools such as ANSYS or equivalent.
- Extensive background in developing and improving composite manufacturing processes in both R&D and high throughput production environments.
- Excellent communication, teamwork, and problem-solving skills.
Preferred Qualifications:- Advanced understanding of composite processing techniques (e.g., autoclave curing, resin infusion, precision layup) and quality assurance methodologies.
- Experience with CAD/CAM software for tooling and fixture development.
- Familiarity with lean manufacturing principles or Six Sigma practices.
- A proactive, hands-on approach with strong analytical and technical aptitude.
