Process Engineer - Thermal Spray

Kymera International - Corrosion and Abrasion Solutions (USA) Ltd • Westfield, TX

5h • Hybrid

About The Position

The Thermal Spray Process Engineer plays a critical dual role in managing and optimizing technical operations for shipboard and shop projects, from initial proposals through project closeout. This position combines process engineering expertise—particularly in thermal spray technologies—with project engineering responsibilities, including design layout, estimating, and execution oversight. The engineer ensures that projects are accurately scoped, technically sound, and delivered on time, within budget, and in compliance with quality, safety, and customer specifications.

Requirements

• 5+ years of technical planning, process, and project engineering experience.
• Strong knowledge of thermal spray technologies, process parameters, and equipment setup.
• Proficiency with CAD software and Microsoft Office Suite.
• Ability to manage multiple priorities in a fast-paced, deadline-driven environment.
• Exceptional analytical and problem-solving skills with a continuous improvement mindset.
• Excellent written and verbal communication skills for collaboration with teams and customers.
• Ability to thrive in a dynamic, flexible work environment where roles may blend across functions.
• Experience with estimating, project scheduling, and resource allocation.
• Must be a "US Person" under ITAR requirements and able to pass all necessary background checks and security clearances, including DBIDS credentialing.
• Possess and maintain a valid driver’s license with a satisfactory driving record, to operate a rental or company vehicle.
• Ability to travel to domestic and international up to 50%.
• Bachelor’s or Associate degree in Mechanical Engineering, Manufacturing Engineering, or related field, or equivalent experience.
• Minimum 5 years’ experience in manufacturing, machining, thermal spray process engineering, or project engineering roles.
• Experience in job shop or service-oriented, high-mix/low-volume production preferred.

Responsibilities

• Collaborate with Sales and Marketing to review project proposals and scopes as outlined in Requests for Proposal (RFQ).
• Develop detailed project layouts, schedules, and workflows for efficient execution.
• Read and interpret blueprints and technical drawings; utilize CAD software for tooling and project overlays.
• Develop Process Control Plans (PCPs) including documentation and drawings, creating a catalog aligned with product lines.
• Create user and training manuals based on PCPs to support workforce knowledge and project execution.
• Implement new product introductions, including tooling design and robotic programming where applicable.
• Lead software integrations related to process control, estimating, budgeting, and inspection.
• Support estimating efforts, ensuring accurate calculation of hours, materials, tools, equipment, personnel, and subcontractor requirements.
• Evaluate customer requirements and technical drawings to develop precise quotes and job estimates.
• Design, refine, and document thermal spray (HVOF, plasma, arc spray, grit blast), machining, and auxiliary processes to improve quality, efficiency, and consistency.
• Serve as the technical subject matter expert for all thermal spray systems and associated equipment.
• Conduct root cause analyses and implement corrective actions to optimize production workflows and coating quality.
• Manage vendor relationships for process equipment, raw materials, and upgrades.
• Troubleshoot and lead upgrades to equipment and systems to enhance reliability and capability.
• Maintain detailed technical documentation, process instructions, and job travelers.
• Train and mentor operators and technicians on process execution, troubleshooting, and safety compliance.
• Ensure technical training and compliance to meet business objectives.
• Drive enhancements in quality, health, and safety (EH&S) standards.
• Develop team performance metrics and support cross-departmental process controls.
• Adapt to changing business priorities and undertake other duties as assigned.
• This role may have supervisory responsibilities in the future.

Benefits

• Generous Time Off: 11 annual company-paid holidays and flexible PTO.
• Healthcare Savings: Flexible Spending Accounts (FSA), Health Savings Accounts (HSA), and comprehensive dental and vision coverage.
• Retirement Support: 401(k) plan with a competitive company match.
• Insurance Coverage: Company-paid short-term disability and life insurance, with additional voluntary options like critical illness, hospital care, and long-term disability coverage.
• Competitive pay.
• Team Benefits: A supportive team culture and resources to help you thrive.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Education Level: Associate degree