Aerospace Process Engineer - Molding and Spray Coatings

Chromalloy•Windsor, CT

4d•$89,840 - $117,915•Onsite

About The Position

Chromalloy is seeking a Process Engineer – Molding & Spray Coatings to support the repair and overhaul of critical gas turbine engine components used in commercial aerospace applications. The position develops, optimizes, and sustains manufacturing processes involving resin molding, protective coatings, chemical cleaning, acid etching, and blending to improve product quality, process capability, operational efficiency, and on-time delivery. The role is based on-site in Windsor, Connecticut, and requires occasional travel. The employee works in office and manufacturing environments, regularly interacting with production areas, laboratories, and repair operations. Work outside regularly scheduled hours may be required to meet operational needs, including evenings, weekends, or holidays. Additional hours are assigned based on business requirements; non-exempt employees receive overtime pay as required by applicable law. Only U.S. persons, as defined in the posting, may be considered. Chromalloy is an equal opportunity employer and provides a contact for applicants who need a disability-related accommodation during the online application process.

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.
Must be a U.S. person as defined in the posting.
Ability to stand, walk, bend, reach, and move throughout manufacturing facilities for extended periods.
Ability to occasionally lift and carry up to 25 pounds.
Ability to wear required personal protective equipment and comply with safety policies and procedures.

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 tooling and fixturing for manufacturing applications.
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, to improve part quality and process repeatability.
Develop and refine resin molding processes, including material selection, mix ratios, cure schedules, and manual injection techniques.
Troubleshoot manufacturing defects such as voids, incomplete fill, shrinkage, and dimensional nonconformances, and implement corrective actions to improve quality and yield.
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 to enhance product quality and consistency.
Develop standardized blending techniques, procedures, and best practices across manufacturing operations.
Monitor process performance and drive initiatives to improve safety, quality, delivery, and cost.