Composite Materials & Process Engineer

General Plastics & Composites LP • Houston, TX

17h • Hybrid

About The Position

This role focuses on materials engineering, process engineering, manufacturing support, testing & failure analysis, and continuous improvement within the field of composite materials. The engineer will be involved in the selection, development, and qualification of composite materials and manufacturing processes. They will also provide technical support to production, investigate manufacturing issues, lead root cause investigations, and support new product introduction. Additionally, the role involves coordinating and performing material and process validation testing, analyzing failures, and preparing technical reports. Continuous improvement efforts will include identifying opportunities to reduce costs and improve efficiency using Lean Manufacturing and Six Sigma methodologies. The position requires a hands-on engineering approach, technical curiosity, structured problem-solving, attention to detail, collaboration, and initiative.

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

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.

What This Job Offers

• Job Type: Full-time
• Career Level: Entry Level