AFP Manufacturing Engineer II-Composites

Firefly Aerospace•Briggs, TX

About The Position

The Automated Fiber Placement (AFP) Engineer develops and optimizes automated composite layup processes and oversees AFP programming using Ingersoll AFP systems. The role supports production and engineering by generating precise ply programs, improving part quality, reducing cycle time, and troubleshooting AFP-related issues in the manufacture of complex aerospace components. The engineer works closely with design engineering, NC programming, operations, quality, and maintenance teams.

Requirements

Bachelor's degree in Mechanical Engineering or a related engineering field.
Five years of experience in carbon-fiber composite aerospace manufacturing.
Automated Fiber Placement experience.
Proficiency in CAD software and AFP programming.
Experience evaluating machine efficiency and implementing process improvements to reduce time and waste.
Strong technical aptitude and ability to quickly become an expert on complex hardware.
Excellent communication skills and ability to collaborate effectively with cross-functional teams.
Demonstrated track record of driving process improvements and delivering results in a fast-paced environment.
High initiative and self-motivation, with the ability to thrive in a dynamic and challenging work environment.
Excellent problem-solving and analytical abilities.

Nice To Haves

Five or more years in an aerospace manufacturing or engineering environment, with a bachelor's degree in mechanical, aerospace, or a similar field.
Experience with capital equipment implementation.
Master's degree.
Six Sigma or Lean manufacturing Black Belt certification.

Responsibilities

Oversee development of AFP ply programs for composite parts using Ingersoll Gen2, Vericut Composite Programming (VCP), and Vericut Composite Simulation (VCS), ensuring conformance to design intent and manufacturing constraints.
Translate engineering models, ply books, and lamination schedules into executable AFP paths with accurate fiber orientation, coverage, and boundaries.
Support Ingersoll machine setup, calibration, and laser alignment for first-article and repeatable production runs.
Analyze and optimize machine pathing to minimize defects such as gaps, overlaps, and tow-steering errors, improve machine efficiency, and extend tool life.
Review and validate AFP programs with simulations and dry runs, working alongside operators during production start-ups.
Collaborate with design engineering to provide design-for-manufacturability feedback for composite parts intended for AFP.
Investigate and resolve machine- and process-related issues, working with maintenance and Ingersoll technical support as needed.
Participate in tooling design reviews to ensure compatibility with AFP head dimensions, access, and laser projection systems.
Implement and document process improvements, material usage reductions, and automation enhancements.
Work with the facilities team to improve critical spares documentation and write preventive maintenance plans.
Develop and maintain standard work instructions, AFP best practices, and process documentation.
Support audits, root cause investigations, and corrective actions involving AFP-manufactured parts.
Maintain composure under pressure while managing multiple deadlines.
Arrive on time and maintain good attendance, which are conditions of employment and essential job functions.
Communicate effectively in spoken and written English.