Principal Engineer – Materials and Process

Ultra Maritime•Dartmouth, NS

About The Position

Unleash the Power of Multi-Mission Excellence: Safeguarding the Seas for the World's Navies. Step into a world where cutting-edge technology meets unparalleled expertise. Ultra Maritime pioneers delivering multi-mission solutions that protect and empower the naval forces worldwide. With our extensive portfolio of capabilities, our innovations are utilised on naval fleets across our allied navies around the globe. As the maritime and underwater battlespace evolves, we tirelessly push the boundaries to develop advanced specialist systems that provide our 'five-eyes' Defence customers with an unbeatable warfighting edge. From surface vessels to sub-surface operations and unmanned platforms, we are revolutionizing the way naval missions are executed. We thrive on collaboration and partnering with our customers to ensure mission success. Our expert solutions encompass an array of game-changing technologies, including state-of-the-art sonar, radar, expendables, signature management, and naval power systems. Join us in shaping the future of naval warfare and together, we will safeguard the seas and empower navies worldwide! The Principal Engineer – Materials is the technical authority for materials across Ultra Maritime’s underwater sensing portfolio, including sonobuoys, sonar systems, acoustic arrays, and ASW technologies. The role is responsible for defining, governing, and optimizing the use of ceramic, polymer, and metallic materials across pressure housings, acoustic windows, structural components, encapsulation systems, and electronic packaging operating in harsh marine environments. The position leads material selection, qualification, modeling, and manufacturing process optimization, and drives the adoption of advanced materials and additive manufacturing (metal 3D printing) for next-generation underwater systems. Candidates must be eligible to obtain the relevant security clearance required for the role, due to the nature of the programmes we deliver for our customers.

Requirements

Master’s or PhD in Materials Science, Metallurgical Engineering, Polymer Engineering, Ceramic Engineering, Mechanical Engineering, or related discipline
12+ years of experience in defense, aerospace, marine, or subsea engineering environments
Strong expertise across metallic, polymer, and ceramic material systems
Deep understanding of corrosion, fatigue, fracture mechanics, pressure effects, and environmental degradation in seawater
Proven experience in process optimization and manufacturing of multi-material systems
Experience in material and process modeling (FEA, fracture mechanics, viscoelastic modeling, thermal and corrosion modeling)
Experience with qualification and testing of mission-critical systems in harsh environments
Technical authority across ceramic, polymer, and metallic material systems
Strong capability in material and manufacturing process optimization
Deep knowledge of corrosion, fatigue, fracture, sealing, and environmental degradation
Experience with acoustic-sensitive and pressure-rated material systems
Strong modeling and simulation capability for multi-material behavior
Knowledge of manufacturing processes (ceramics, polymers, metals, coatings, bonding, AM)
Expertise in qualification, certification, and reliability engineering
Cross-functional technical leadership in complex engineering environments
Bachelor Degree (or equivalent) in a related field and 12+ years experience in a range of roles within a relevant complex engineering environment.
May be required to maintain security clearance.

Nice To Haves

Exposure to sonar, underwater acoustics, or sonobuoy systems is highly desirable
Familiarity with additive manufacturing (metal AM) and qualification frameworks is an asset

Responsibilities

Provides technical leadership for all materials used in sonar and sonobuoy systems operating in extreme subsea conditions, including high hydrostatic pressure, corrosion, vibration, shock loading, and long-duration seawater exposure.
Defines and owns material strategies across metallic, polymer, and ceramic systems, including corrosion-resistant alloys, structural steels and titanium, acoustic-transparent polymers, elastomers, epoxy and polyurethane encapsulants, and functional ceramics used in sensing, insulation, and acoustic applications.
Leads material, polymer, ceramic, and process modeling and optimization, including predictive simulation of corrosion, fatigue, fracture, viscoelastic behavior, thermal response, acoustic transmission, and manufacturing process variability. These models are used to optimize product design, improve reliability, and reduce lifecycle cost and risk.
Leads end-to-end process optimization across material systems, including casting, forging, machining, ceramic processing, polymer molding, curing, adhesive bonding, coating, and encapsulation processes to ensure repeatable quality, high yield, and consistent performance.
Defines and executes material qualification and validation strategies across all material classes, including environmental testing such as pressure cycling, thermal shock, vibration, shock, saltwater immersion, and long-duration aging to ensure compliance with defense and maritime standards.
Leads root cause investigations of material and process-related failures, including corrosion, cracking, ceramic fracture, polymer degradation, delamination, sealing failures, and fatigue, and implements corrective and preventive actions to improve product robustness.
Collaborates closely with systems engineering, acoustics, electronics packaging, and manufacturing teams to ensure material selection supports acoustic performance, structural integrity, and system reliability requirements.
Governs supplier material and process capability across metallic, polymer, and ceramic supply chains, ensuring quality, traceability, and process control consistency for mission-critical components.
Drives innovation in ceramic, polymer, and metallic material systems, including acoustic-optimized materials, high-performance composites, advanced coatings, and environmentally resistant systems for underwater applications.
Defines and executes the roadmap for additive manufacturing (metal 3D printing), including material qualification, process modeling, and deployment for complex geometries, lightweight structures, and sustainment/repair solutions.