Aerospace Process Engineer - Molding and Spray Coatings

Chromalloy; Windsor (CT); On-site; USD 90,000 - 120,000; Full time

Job summary

Chromalloy is seeking an Aerospace Process Engineer to support molding and spray coatings for gas turbine engine components at Windsor, CT. You will design, optimize, and sustain resin molding, coating, cleaning, etching, and blending processes to improve quality, yield, and on-time delivery in an aerospace manufacturing environment.

Responsibilities include process development, troubleshooting, equipment selection, creating work instructions, and cross-functional collaboration with operations,

Qualifications

• Bachelor's degree in Engineering or related science-based discipline.
• 3+ years engineering experience in manufacturing; aerospace experience preferred.
• Experience with resin molding, molding design optimization, and coatings processes.
• Strong communication and cross-functional collaboration skills.

Responsibilities

• Design and optimize resin molding processes and spray coating operations.
• Troubleshoot defects and implement corrective actions to improve quality and yield.
• Provide engineering support to production, including root-cause analysis and continuous improvement.
• Develop tooling, fixtures, and procedures; maintain process documentation.
• Train operators and coordinate with maintenance for preventive programs.

Skills

Aerospace manufacturing

Process development

Root cause analysis

Continuous improvement

Education

Bachelor's degree in Engineering

Tools

Siemens NX

HVLP spray equipment

Job description

Aerospace Process Engineer - Molding and Spray Coatings

601 Marshall Phelps Rd, Windsor, CT 06095, USA

Job Description

Chromalloy is a global engineering & solutions company. We are a leading provider of aftermarket parts, repairs, and solutions that safely & reliably extend the life of aircraft engines and gas turbines. We develop, manufacture and repair critical turbine components for a range of engine platforms. Our solutions support the engines running the aerospace, energy and defense industries around the world.

Chromalloy employees are proud, passionate problem-solvers who strive to live our values every day. A career with Chromalloy is an opportunity to learn from top industry experts, work with important technologies, and unlock a passion for innovation. Join our team of experts, innovators and problem-solvers delivering world-class solutions for our customers. As a global company, we are committed to creating an inclusive environment where all employees feel represented, heard, and able to bring their best selves to work every day. Be part of something bigger with Chromalloy!

Total Rewards Program is designed to support you today and in the future.

• Comprehensive and flexible benefit options starting on day one, including medical, dental, vision, EAP, wellness incentives, and 401(k) with employer matching.
• Development & progression opportunities for every employee – regular performance conversations, training and development curriculum, and engineering fellowship programs.
• Paid time off, including vacation, sick time, paid holidays, and parental leave—all eligible on yourfirst day of employment!
• Competitive pay, including eligibility for quarterly and annual bonuses, depending on role and site.

Eligibility for individual benefit plans may vary based on employment status.

Job Summary

We're looking for a Process Engineer – Molding & Spray Coatings to support the repair and overhaul of critical gas turbine engine components used in commercial aerospace applications. In this role, you will develop, optimize, and sustain manufacturing processes related to resin molding, protective coatings, chemical cleaning, acid etching, and blending operations. Your work will directly improve product quality, process capability, operational efficiency, and on-time delivery of aerospace components.

Work That Matters

At Chromalloy, your work directly supports aviation safety and reliability. Our teams repair and manufacture critical aerospace components used across the global aviation industry. Whether you're improving processes, supporting operations, solving technical challenges, or driving business performance, your contributions help keep aircraft flying safely around the world.

Location : Windsor, CT

Schedule : On-site

What You’ll Be Doing

• Design and optimize low-pressure hand-injected resin molds, including venting, flow paths, parting lines, and release features to improve part quality and process repeatability.
• Develop and refine resin molding processes, including material selection, mix ratios, cure schedules, and manual injection techniques.
• Troubleshoot manufacturing defects such as voids, incomplete fill, shrinkage, and dimensional nonconformances, implementing corrective actions to improve quality and yield.
• Provide day-to-day engineering support for production operations, including root cause analysis, corrective actions, and continuous improvement initiatives.
• Lead the design, development, procurement, and implementation of process tooling, fixtures, gauging, and equipment required to support production cells.
• Establish and maintain process documentation, including work instructions, operating procedures, specifications, calibration instructions, and quality records.
• Support operator training and work closely with maintenance teams to implement effective preventive maintenance programs.
• Develop and optimize HVLP spray coating processes for aerospace-grade protective coatings.
• Improve chemical cleaning, acid etching, and surface preparation processes to enhance product quality and consistency.
• Develop standardized blending techniques, procedures, and best practices across manufacturing operations.
• Monitor process performance and drive initiatives that improve safety, quality, delivery, and cost.

What We’re Looking For

• Bachelor's degree in Engineering or a related science-based discipline such as Materials Science, Chemistry, or Physics.
• 3+ years of engineering experience in a manufacturing environment; aerospace, MRO, or gas turbine component repair experience preferred.
• Experience with low-pressure or hand-injected resin molding processes and mold design optimization.
• Working knowledge of process development, troubleshooting, root cause analysis, and corrective action methodologies.
• Experience supporting production operations and driving continuous improvement initiatives.
• Ability to interpret technical drawings, specifications, and engineering documents.
• Strong written and verbal communication skills with the ability to collaborate across operations, quality, engineering, and maintenance teams.

Nice to Have

• Experience within aerospace manufacturing, repair, or overhaul environments.
• Proficiency with 3D CAD modeling software such as Siemens NX.
• Experience designing tooling and fixturing for manufacturing applications.
• Knowledge of aerospace protective coating systems, including:
  • Polyurethane coatings
  • Epoxy coatings
  • Aluminized coatings
• Experience with HVLP spray equipment and process optimization.
• Experience with chemical cleaning and acid etching of aerospace alloys.
• Knowledge of aerospace blending techniques and tooling selection.
• Familiarity with Lean Manufacturing, Six Sigma, or continuous improvement methodologies.

Work Environment & Physical Requirements

• Work is performed in both office and manufacturing environments with exposure to production equipment, machinery, and industrial processes.
• Regular interaction with production areas, laboratories, and repair operations is required.
• Ability to stand, walk, bend, reach, and move throughout manufacturing facilities for extended periods.
• Ability to occasionally lift and carry up to 25 pounds.
• Must be able to wear required personal protective equipment (PPE) and comply with all safety policies and procedures.

This position may require work hours outside of the regularly scheduled hours to meet operational needs. This may include work during evenings, weekends, and/or holidays. Additional work hours are assigned based on business requirements. Non-exempt employees will be paid overtime in accordance with applicable federal, state, and local laws.

The salary range for this position reflects a broad spectrum of experience levels. Individual compensation within the range is determined by multiple factors, including relevant experience, education, certifications, job related skills, internal equity, and market conditions. We evaluate each candidate individually to ensure fair and competitive pay decisions.

Due to government regulation only US persons (U.S. citizen, U.S. naturalized citizen, U.S. permanent resident, holder of U.S. approved political asylee or refugee status) may be considered for this role.

Chromalloy participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.

Any offer of employment will also be conditioned upon the successful completion of a background investigation and drug screen in accordance with company policy and applicable federal and state regulations.

Chromalloy is an equal opportunity employer - vets/disabled.

601 Marshall Phelps Rd, Windsor, CT 06095, USA