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Materials Process Engineer

2 months ago

Irvine, California, United States Supernal Full time
About the Role

We are seeking a highly skilled and experienced Lead Materials Engineer to join our team at Supernal, a leading Advanced Air Mobility company. As a key member of our Engineering team, you will be responsible for developing and implementing conventional and novel materials and process solutions to support the design and production of our electric vertical take-off and landing (eVTOL) vehicle.

Key Responsibilities
  • Develop and implement materials and process solutions to support the design and production of our eVTOL vehicle
  • Collaborate with cross-functional teams, including Engineering and Supply Chain, to ensure that delivered hardware meets requirements and leads to certification and production
  • Own the evaluation and selection of composite materials and adhesives to satisfy design requirements
  • Coordinate the development of adhesively bonded joints and assemblies
  • Build internal material specifications and process specifications that support manufacturing and ensure quality
  • Lead and coordinate testing for method development, materials characterization, allowables generation, and design validation
  • Serve as the M&P representative in design reviews, the production drawing release cycle for hardware components/assemblies, and Material Review Board (MRB) issues
  • Coordinate supplier selection, development, qualifications, and ongoing evaluations
  • Build procedures for reviewing supplier-delivered hardware for compliance with requirements
  • Assist in building top-level M&P control plans and documentation
  • Support the manufacture of hardware in-house and at our suppliers
  • Participate in industry working groups, standards bodies, and relevant technical conferences and symposia to maintain awareness of technology developments and regulatory trends
  • Mentor junior engineers
  • Partner with PMO organization to implement build plan
  • Up to 25% of domestic and international travel
  • May occasionally support 2nd, 3rd shift or weekend shift
  • Other related duties as assigned
Requirements
  • Bachelor's Degree in STEM or related field required; Master's or Ph.D. degree preferred
  • Minimum ten (10) years of experience in related experience (an equivalent combination of education and experience may be considered)
  • Experience in thermoset fiber composites, thermoplastic fiber composites, structural bonding, adhesives, plastics, physical and mechanical material characterization, composite material allowables generation and certification
  • Experience with qualification and implementation of automated/robotic composite processes
  • Experience with process mapping, SPC, PFMEA, DFMEA, and similar tools/techniques
  • Knowledge of a first principles' approach to problem-solving
  • Familiarity with 3D CAD software (CATIA, SolidWorks, NX, or similar)
  • Proficiency at drafting test plans, coordinating and implementing test campaigns, and generating test reports
  • Knowledge and ability to run materials characterization lab equipment such as FTIR, DSC, SEM, TGA, Rheometer, and Instrons
  • Ability to perform composite layups and bagging and run equipment related to composite fabrication
  • Ability to lift/move equipment and tools weighing up to 35 lbs
  • Familiarity with statistical software, including Minitab, JMP, or similar
  • Knowledge of CMH-17, SAE, ASTM, and other standard bodies
  • Understanding of Six Sigma, Lean, and DOE principles
  • Proficiency in writing R&D work instructions and documentation of R&D work
  • Understanding of composites and adhesive materials and processing methods used for various applications found in aircraft structures
  • Understanding of materials and processes outside of composites and structural bonding
  • Ability to lead material allowable certification programs
  • Fabrication methods in a high-rate manufacturing environment
  • Proficiency in MS Office Suite tools such as Word, Excel, Project, and Visio
  • Proactive and efficient delivery of communication and follow-up
  • Excellent organizational skills and attention to detail
  • Must have the ability to independently prioritize and accomplish work in a timely manner
Preferred Qualifications
  • Six Sigma Green Belt or higher preferred
  • Experience with aerospace assembly processes preferred