Senior Composite Manufacturing Engineer

2 weeks ago

Hyderabad, Telangana, India skyroot Full time
Roles and Responsibilities
  1. Project Allocation: Ensure projects are allocated to the composite manufacturing engineering team with technical inputs on safety, on-time delivery, and within budget.
  2. Document Review: Prepare, review, and obtain approvals of detailed work instructions, procedures, PFMEAs, and JSAs that meet design process quality, safety, and environmental requirements.
  3. Manufacturing Expertise: Possess hands-on experience on advanced composite manufacturing processes like filament winding, machine programming, and operation of hand layup, RTM, VARIM, and prepreg technologies, along with knowledge of core processing techniques.
  4. Design Support: Analyze engineering drawings and specifications to support design development and manufacturing of robust and advanced part and tooling designs, including concepts and proving of hardware, molds, assembly, trimming, and drilling.
  5. Material Testing: Knowledge and understanding of relevant composite material testing are advantageous.
  6. Work Instructions: Create work instructions for end-to-end composite component manufacture (laminating through to assembly and paint) to support a Right First Time philosophy.
  7. Documentation: Sound knowledge on documentation for Design, Manufacturing, Quality, and FAI.
  8. GD&T: Good knowledge in GD&T with Catia V5/SolidWorks experience.
  9. Technical Guidance: Provide technical manufacturing inputs and guidance to shop floor design, quality, and management teams.
  10. Raw Material Selection: Strong knowledge of raw material selection, qualification, reporting, and analysis.
  11. Interface Management:
  12. Quality Assurance: Perform investigations of nonconforming hardware and implement corrective actions to prevent future occurrences.
  13. Customer Presentations: Present fabrication processes at customer readiness reviews and present process changes to customers at change board meetings.
  14. Additional Skills: Compression molding with rubber molding compounds and/or prepreg is strongly desired; hand layup and cure of insulation and other ablative materials are required; surface preparation for primary substrates to bond rubber or composite is desired; autoclave and digital cutting table programming and operation are a plus.
Desired Skills
  1. Experience: Must have at least 46 years of experience within the composites manufacturing industry.
  2. Supply Chain Management: Must have experience with supply chain management and the development of vendors for fabrication.
  3. Composites Manufacturing Processes: Must have a good understanding of various composites manufacturing processes and equipment used, such as filament winding, tape winding, compression molding, resin transfer molding, hand layup, and prepregging.
  4. Filament Winding: Must have experience with filament winding in proving out composite motor casing (CRMC) composite vehicle sections, launch tubes, and nozzles.
  5. CNC Machines: Must be able to showcase skills in operating 4 & 5 axis CNC filament winding machines, autoclaves, & ovens, tape winding machines, hydraulic press, etc.
  6. Bonding Techniques: Knowledge on various bonding techniques between dissimilar materials interfaces, such as metals, composites, elastomers, and metals.
  7. Raw Material Qualification: Should be familiar with raw materials qualification standards (ASTM/BS/IS etc) for metallics and composites.
  8. Quality Acceptance: Must know in-process and final quality acceptance of launch vehicle composite hardware realized through filament winding, hand layup, and other processes both through conventional and NDT techniques.
  9. Fluctuating Demands: Ability to act quickly on fluctuating demands and coordinate well with internal teams for closure and be responsible for the manufacturing of the hardware.

Additional Requirements: Experience in QA/QC in precision assemblies & testing of mechanical systems; knowledge in preparing Quality Assurance Plans/Quality Assessment report for new products; knowledge in raw material testing standards such as ASTM/AMS for metallics; familiarity with quality acceptance standards for aerospace grade fasteners, springs, & seals desirable.

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