Aerospace Process Engineer - Molding and Spray Coatings

Chromalloy•Windsor, CT

3d•Onsite

About The Position

The Aerospace Process Engineer – Molding and Spray Coatings supports the repair and overhaul of critical gas turbine engine components used in commercial aerospace applications. The role develops, optimizes, and sustains manufacturing processes related to resin molding, protective coatings, chemical cleaning, acid etching, and blending operations, with the aim of improving product quality, process capability, operational efficiency, and on-time delivery. The position is based on-site in Windsor, Connecticut, and requires occasional travel. Work takes place in office and manufacturing environments, with regular interaction with production areas, laboratories, and repair operations. The engineer supports aviation safety and reliability by improving processes and supporting the manufacture and repair of critical aerospace components.

Requirements

Bachelor's degree in Engineering or a related science-based discipline, such as Materials Science, Chemistry, or Physics.
At least 3 years of engineering experience in a manufacturing environment.
Experience with low-pressure or hand-injected resin molding processes and mold design optimization.
Working knowledge of process development, troubleshooting, root cause analysis, and corrective action methodologies.
Experience supporting production operations and driving continuous improvement initiatives.
Ability to interpret technical drawings, specifications, and engineering documents.
Strong written and verbal communication skills and ability to collaborate across operations, quality, engineering, and maintenance teams.

Nice To Haves

Aerospace, MRO, or gas turbine component repair experience.
Experience in aerospace manufacturing, repair, or overhaul environments.
Proficiency with 3D CAD modeling software such as Siemens NX.
Experience designing manufacturing tooling and fixturing.
Knowledge of aerospace protective coating systems, including polyurethane, epoxy, and aluminized coatings.
Experience with HVLP spray equipment and process optimization.
Experience with chemical cleaning and acid etching of aerospace alloys.
Knowledge of aerospace blending techniques and tooling selection.
Familiarity with Lean Manufacturing, Six Sigma, or continuous improvement methodologies.

Responsibilities

Design and optimize low-pressure hand-injected resin molds, including venting, flow paths, parting lines, and release features.
Develop and refine resin molding processes, including material selection, mix ratios, cure schedules, and manual injection techniques.
Troubleshoot manufacturing defects, including voids, incomplete fill, shrinkage, and dimensional nonconformances, and implement corrective actions.
Provide day-to-day engineering support for production operations, including root cause analysis, corrective actions, and continuous improvement initiatives.
Lead the design, development, procurement, and implementation of process tooling, fixtures, gauging, and equipment for production cells.
Establish and maintain process documentation, including work instructions, operating procedures, specifications, calibration instructions, and quality records.
Support operator training and work with maintenance teams to implement preventive maintenance programs.
Develop and optimize HVLP spray coating processes for aerospace-grade protective coatings.
Improve chemical cleaning, acid etching, and surface preparation processes.
Develop standardized blending techniques, procedures, and best practices across manufacturing operations.
Monitor process performance and drive initiatives to improve safety, quality, delivery, and cost.