Composite Materials & Process Engineer

Johns Hopkins Applied Physics Laboratory•Laurel, MD

About The Position

Do you thrive in a dynamic, high-energy, customer-focused environment? Are you passionate about using state of the art materials and processes to develop sponsor solutions? Are you excited about researching new materials to improve product performance? Do you have a broad background in polymer and composite materials and processes, facilities, and fabrication equipment? If so, we’re looking for someone like you to join our team at APL! We are seeking an experienced Composite Materials and Process Engineer to support the Mechanical Fabrication Group at APL. In this role you will work closely with APL partners to serve as an engineering resource for conducting advanced composites design, fabrication, research and development in support of all programs and mission areas. From deep underwater to far in space, you will support the design, material selection, fabrication, and testing for those composite assemblies. As a recognized materials expert, you will identify opportunities for innovative application of composite technologies in new and ongoing programs and serve as a technical resource to APL staff in delivering the highest-quality products. As a Materials and Process Engineer you will: Provide technical leadership in the selection, development, qualification, and implementation of advanced composite materials and manufacturing processes in support of complex mechanical systems. You will be expected to possess a comprehensive understanding of composite constituents, including fiber reinforcements, textiles, and both thermoset and thermoplastic resin systems. This role spans the full lifecycle of composite hardware, from material down-selection and process development through fabrication, testing, and transfer to industry. Apply deep knowledge of resin chemistries, material properties, and processing–performance relationships to define robust, repeatable manufacturing processes. Responsibilities include selecting and qualifying composite materials, developing detailed process specifications and work instructions, and supporting fabrication activities such as prepreg hand layup, tape wrapping, resin infusion, consolidation, curing, and post-processing. You will routinely work hands-on in the lab or shop to conduct process trials, support prototype and production builds, and troubleshoot fabrication issues related to defects, variability, or performance shortfalls. Support structural design and analysis efforts through a working understanding of composite mechanics and laminate theory. This includes performing laminate analyses to predict material properties and advising designers on ply stacking sequences, fiber orientations, and material trade studies, and collaborating with analysts to ensure assumptions are consistent with manufacturing realities. Example work may include supporting the design of load-bearing composite structures, sandwich panels, and integrated composite assemblies. Help plan and oversee material characterization and qualification efforts, selecting appropriate ASTM test methods to generate mechanical, thermal, and environmental property data and material allowables. This includes working with test laboratories, analyzing results, and ensuring data is suitable for design and use. Through a balance of materials science expertise, hands-on fabrication experience, and analytical understanding, you will ensure reliable, high-performance composite solutions across a wide range of applications.

Requirements

A Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Materials Science, Physics, or a related field.
At least 8+ years of experience working with composite reinforcements, resins, prepregs, adhesives, cores, fabrication methods, tooling, and machining.
Knowledge of materials and mechanical design.
Experience using CAD to generate designs for layup and assembly tooling.
Strong understanding of composite design, fabrication, processing, and testing.
Experience in composites and bonded assembly process development; and ability to solve common engineering problems including the documentation and communication of the work.
Knowledge in high temperature composite materials and processes.
A strong background of hands-on fabrication.
Excellent oral and written communications skills.
Ability to work independently and exercising good technical judgment and communicate effectively while working in a team.
Ability to travel to field sites to support materials engineering tasking.
Ability to meet physical requirements for working with ordnance.
Are able to obtain an Interim Secret level security clearance by your start date and can ultimately obtain a Top Secret security level clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship.

Nice To Haves

A MS in Mechanical/Materials Engineering.
Significant experience with aerospace advanced composites and bonded assembly fabrication and processing methods to include autoclave cure and post processing methods.
Experience developing tooling to support component fabrication.
Experience in laminate analysis.
Expertise in operating controllers for computer controlled autoclaves and other processing equipment.

Responsibilities

Provide technical leadership in the selection, development, qualification, and implementation of advanced composite materials and manufacturing processes in support of complex mechanical systems.
Apply deep knowledge of resin chemistries, material properties, and processing–performance relationships to define robust, repeatable manufacturing processes.
Support structural design and analysis efforts through a working understanding of composite mechanics and laminate theory.
Help plan and oversee material characterization and qualification efforts, selecting appropriate ASTM test methods to generate mechanical, thermal, and environmental property data and material allowables.