Composite Materials & Process Engineer

GP&C•Houston, TX

1d•Hybrid

About The Position

This role involves a blend of Materials Engineering and Process Engineering focused on composite materials. The engineer will be responsible for evaluating and selecting composite materials, developing and maintaining material specifications, and performing material testing. They will also be involved in developing, documenting, and improving composite manufacturing processes, establishing process specifications, and supporting various manufacturing methods. Additionally, the role requires providing technical support to production, investigating manufacturing issues, leading root cause investigations, and supporting new product introduction. The engineer will also coordinate testing, perform failure analysis, and contribute to continuous improvement initiatives using methodologies like Lean Manufacturing and Six Sigma. Collaboration with operators, supervisors, and customers for technical reviews and audits is also a key aspect of the position.

Requirements

Bachelor's degree in Materials Science, Mechanical Engineering, Aerospace Engineering, Chemical Engineering, Manufacturing Engineering, or a related discipline.
2+ years of experience in composites engineering, manufacturing engineering, materials engineering, or a related role.
Experience with composite manufacturing processes and materials.
Knowledge of polymer matrix composites and composite fabrication methods.
Experience interpreting engineering drawings and technical specifications.
Familiarity with manufacturing documentation, process controls, and quality systems.
Carbon fiber composites.
Fiberglass composites.
Thermoset resin systems
Epoxy systems
Vinyl ester resins
Core materials and adhesives
Composite bonding technologies
Vacuum infusion
Autoclave processing
Prepreg manufacturing
Cure cycle development
Process validation
Tooling and fixture development
Manufacturing process controls
Root Cause Analysis (5 Why, Fishbone, 8D)
Statistical Process Control (SPC)
PFMEA
Design of Experiments (DOE)
Data analysis and reporting

Nice To Haves

Experience in aerospace, defense, energy, industrial equipment, marine, automotive, or sporting goods industries.
Familiarity with composite material testing standards (ASTM, ISO, SAE, or equivalent)
Understanding of composite inspection methods including ultrasonic and non-destructive testing (NDT)
Experience performing failure analysis and root cause investigations.
Exposure to Lean Manufacturing, Six Sigma, or continuous improvement methodologies.
Strong analytical and troubleshooting skills.
Excellent written and verbal communication skills
Hands-on engineering approach
Technical curiosity and continuous learning
Structured problem solving
Strong attention to detail
Cross-functional collaboration
Project management
Initiative and accountability
Customer-focused mindset

Responsibilities

Evaluate and support the selection of composite materials, including carbon fiber, fiberglass, aramid fibers, core materials, adhesives, and resin systems.
Develop, maintain, and update material specifications, standards, and qualification requirements.
Perform material testing and characterization to verify mechanical, thermal, and environmental performance.
Review supplier-provided material data and support material qualification and approval processes.
Assess material alternatives by comparing performance, manufacturability, availability, and cost to recommend the most suitable solution for each application.
Support the evaluation, qualification, and implementation of new materials and advanced composite technologies to improve product performance and manufacturability.
Develop, document, and improve composite manufacturing processes.
Establish process specifications, manufacturing instructions, and quality requirements.
Support manufacturing methods including: Hand layup, Vacuum bagging, Resin infusion (VARTM), Resin Transfer Molding (RTM), Compression molding, Injection molding, Prepreg layup, Autoclave curing, Oven curing, Composite assembly and bonding.
Define critical process parameters and process control methods.
Support process validation and qualification activities.
Provide day-to-day technical support to production operations.
Investigate manufacturing issues involving defects, yield loss, porosity, delamination, dimensional variation, or cure-related concerns.
Lead root cause investigations and corrective action implementation.
Collaborate with operators and supervisors to improve process consistency and productivity.
Support manufacturing readiness activities for new product introduction (NPI).
Coordinate and perform material and process validation testing.
Analyze failures related to composite structures, bonding, environmental exposure, and manufacturing defects.
Prepare technical reports summarizing findings and recommendations.
Support qualification testing for customer and regulatory requirements.
Identify opportunities to reduce scrap, rework, cycle time, and manufacturing costs.
Apply Lean Manufacturing and Six Sigma methodologies to process improvement projects.
Analyze manufacturing and quality data to improve process capability and repeatability.
Support automation and advanced manufacturing initiatives.
Support customer technical reviews and audits when required.