Lead Composites Engineer, Tooling & Manufacturing

PteroDynamics•Colorado Springs, CO

6d•Onsite

About The Position

PteroDynamics Inc. is seeking a Lead Composites Engineer to own composite tooling and manufacturing processes in a fast-moving aerospace environment. The role develops tooling, refines fabrication methods, and transitions composite components from prototype work to repeatable production. The engineer works closely with design engineers and manufacturing technicians to improve manufacturability, optimize production, and introduce materials and techniques that support growing operations. The position balances CAD-based tooling design with hands-on shop-floor troubleshooting and practical solutions for performance, quality, and efficiency. The role is based on-site in Colorado Springs, Colorado, and includes occasional travel of less than 5% to support suppliers, tooling vendors, and testing activities. The candidate must be authorized to work for any U.S. employer; visa sponsorship or transfer is not available. The position requires the ability to lift up to 50 pounds. PteroDynamics designs autonomous vertical takeoff and landing aircraft. Its Transwing aircraft transitions between vertical and horizontal flight and is intended for applications such as maritime logistics, delivery to remote locations, and reconnaissance and surveillance. The company describes its values as People, Excellence, Accountability, and Knowledge. The company offers a comprehensive compensation package including competitive salary, stock options, company-sponsored medical insurance, dental, vision, life insurance, a 401(k) plan with company matching, long-term disability, paid time off, paid holidays, paid sick time, and a collaborative, inclusive working environment. Applications are accepted for 60 days beyond the posting date or until the position is filled, whichever comes first.

Requirements

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Materials Science, or a related field.
At least 5 years of engineering experience with advanced composite structures, including significant hands-on composite tooling and manufacturing experience.
Demonstrated experience designing composite tooling and implementing it in a production environment.
Hands-on experience with composite fabrication processes, including prepreg or wet layup, vacuum bagging, oven or autoclave curing, and resin infusion.
Strong understanding of composite laminate design, ply orientation, stacking sequences, core materials, and structural material selection.
Proficiency with CAD software such as SolidWorks, CATIA, or equivalent, including surface modeling and mold/tool design.
Experience performing composite FEA or applying structural analysis results to laminate design and engineering decisions.
Experience conducting DFM/DFA reviews and collaborating with design engineers to improve manufacturability.
Ability to develop clear manufacturing procedures, process specifications, work instructions, and technical documentation.
Strong analytical and problem-solving skills, sound engineering judgment, data-driven decision-making, and a hands-on shop-floor mindset.
Excellent written and verbal communication skills and ability to collaborate proactively across design engineering and manufacturing teams.
Ability to work independently, manage shifting priorities, and drive projects to completion in a fast-paced, experimental environment.
Ability to work on-site in Colorado Springs, Colorado.
Ability to lift up to 50 pounds.
Ability to travel occasionally, less than 5%, to support business needs.
Authorization to work for any employer in the United States; the employer is unable to sponsor or take over sponsorship of an employment visa.

Nice To Haves

Experience developing composite structures for aerospace, unmanned aircraft systems, or other weight-critical applications.
Experience with composite design and analysis tools such as Fibersim, CATIA Composites Design, Femap/Nastran, Abaqus, or ANSYS Composite PrepPost.
Knowledge of CMH-17 (MIL-HDBK-17), composite material allowables, and aerospace composite process specifications.
Experience with CNC-machined tooling, computer-aided manufacturing, or CNC router programming for tooling and master patterns.
Experience with sandwich composite construction, including honeycomb and foam cores, and bonded assemblies.
Familiarity with nondestructive inspection methods, including tap testing, ultrasonic inspection, and composite repair.
Experience establishing or expanding composite manufacturing operations, including equipment selection, process qualification, and technician training.
Familiarity with product lifecycle management, product data management, configuration control, and engineering change processes.
Knowledge of AS9100 or comparable aerospace quality management systems.
Experience working in a startup or rapidly evolving manufacturing environment with changing priorities and limited resources.

Responsibilities

Design and develop composite tooling, including molds, master patterns, plugs, trim and drill fixtures, bonding and assembly jigs, and handling fixtures.
Select tooling materials and manufacturing methods according to part geometry, cure requirements, production needs, and cost.
Develop and implement composite manufacturing processes, including prepreg and wet layup, vacuum bagging, oven and out-of-autoclave curing, resin infusion, core integration, and secondary bonding.
Create and maintain manufacturing documentation such as ply books, cut files, layup sequences, bagging procedures, cure cycles, and standardized work instructions.
Lead the transition of composite components from prototype to repeatable production, improving quality, efficiency, yield, and cost.
Collaborate with design engineers on laminate schedules, ply orientations, material selection, and structural analysis for aircraft development.
Perform or support composite finite element analysis and laminate calculations to inform engineering and manufacturing decisions.
Lead Design for Manufacturing and Design for Assembly reviews to improve manufacturability, tooling, tolerances, and assembly processes.
Evaluate new composite materials, tooling technologies, and manufacturing processes through research, testing, and prototype development.
Troubleshoot manufacturing defects, conduct root-cause analysis, and implement corrective actions to improve production quality.
Support material and process validation through test panels, coupon testing, and qualification activities.
Coordinate with suppliers and vendors on composite materials, tooling fabrication, equipment, and outsourced components.
Support composite shop operations, including equipment selection, facility layout, and safe material handling practices.
Maintain accurate technical documentation and configuration control for tooling, manufacturing processes, and work instructions.
Travel occasionally, less than 5%, to support suppliers, tooling vendors, and testing activities.