Aerospace Process Engineer: Molding & Spray Coatings

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

Job summary

Chromalloy in Windsor, CT seeks a Process Engineer – Molding & Spray Coatings to support repair and overhaul of critical turbine components. You will develop, optimize, and sustain processes for resin molding, protective coatings, chemical cleaning, acid etching, and blending to improve quality, cost, and on-time delivery.

The role requires hands-on process development, tooling design, and collaboration with operations, quality, and maintenance teams in an on-site environment.

Qualifications

• Bachelor's degree in Engineering or related discipline is required.
• 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.

Responsibilities

• 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.

Education

Bachelor's degree in Engineering or related discipline

Tools

Siemens NX

Job description

Chromalloy in Windsor, CT seeks a Process Engineer – Molding & Spray Coatings to support repair and overhaul of critical turbine components. You will develop, optimize, and sustain processes for resin molding, protective coatings, chemical cleaning, acid etching, and blending to improve quality, cost, and on-time delivery.

The role requires hands-on process development, tooling design, and collaboration with operations, quality, and maintenance teams in an on-site environment.