Special Process Engineer – Metal Spray (LPPS, Plasma Spray, HVOF)
About The Position
We are seeking a talented and detail-oriented engineer who thrives in a fast-paced aerospace repair environment. The ideal candidate will take ownership of technical processes from development through implementation and sustainment. Key responsibilities include creating and optimizing work instructions, developing robust processes, validating results through first-article or qualification runs, and driving continuous improvement initiatives that enhance quality, efficiency, and cost-effectiveness. This role requires strong technical expertise, excellent problem-solving skills, and the ability to provide hands-on support to production teams while ensuring full compliance with specifications and regulatory requirements. The successful candidate demonstrates exceptional attention to detail, strong time-management skills, and a proactive mindset focused on process optimization and root-cause resolution. Outstanding candidates are highly organized, collaborative, and capable of communicating complex technical concepts clearly — both verbally and visually — to technical and non-technical stakeholders alike. Responsible for developing, qualifying, and sustaining thermal spray processes (LPPS, Plasma Spray, and HVOF) for aerospace component repair and restoration. Ensures processes meet OEM specifications, FAA Part 145 requirements, and internal quality standards while driving continuous improvement in coating quality, efficiency, and safety.
Requirements
- High school diploma or GED.
- Experience with Metco 9MB or similar plasma systems, HVOF, and LPPS.
- Strong knowledge of coating materials (e.g., MCrAlY, TBCs, ETC).
- Ability to read and interpret design blueprints and manufacturing operation travelers
- Excellent communication skills, both verbal and written.
- Ability to write clear and comprehensive technical documentation.
- Strong organization skills.
- Extensive experience with computer modeling software.
- Proficiency in Microsoft Office.
- Strong analytical thinker.
- Strong attention to detail.
- Ability to work independently and to collaborate with others.
- Ability to complete projects on time and to specification.
- Ability to stand for extended periods.
- Ability to work after-hours when required.
Nice To Haves
- Bachelor’s degree in engineering or a relevant discipline
Responsibilities
- Reading and interpreting technical blueprints and design models.
- Inputting the product design into the computer modeling software.
- Develop and qualify spray parameters for LPPS, Plasma (e.g., Metco 9MB), and HVOF systems.
- Troubleshooting issues during the manufacturing process.
- Completing quality control tests during the manufacturing stage and on the final product.
- Create and maintain process documentation, including work instructions, routers, and technical data sheets.
- Collaborate with quality and production teams on process validation and continuous improvement.
- Drawing up schedules and budgets for higher level projects.
- Evaluating existing manufacturing processes and identifying areas for improvement.
- Determining problem resolutions and implementing improvements.
- Researching and developing new processes, equipment, and products.
- Developing and implementing cost-saving measures and quality control systems.
- Writing technical documentation for operators.
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What This Job Offers
Job Type
Full-time
Career Level
Mid Level
Education Level
High school or GED
