Aerospace Process Engineer - Thermal Spray Coating

States HR CO; Milford (CT); On-site; USD 90,000 - 120,000; Full time

Job summary

States HR CO seeks a Thermal Spray Process Engineer to support repair, overhaul, and manufacturing of critical gas turbine components. The role focuses on developing, implementing, and optimizing thermal spray coating processes for aerospace hardware, with emphasis on production readiness and process capability.

You will monitor yield, drive continuous improvement, train operators, and collaborate with operations, quality, engineering, and maintenance teams while applying Six Sigma and Lean

Qualifications

• Bachelor's degree in Engineering or a related field.
• 3+ years of engineering experience in a manufacturing environment.
• Experience in aerospace MRO or gas turbine environments preferred.
• Experience with process development, manufacturing operations, and continuous improvement.
• Knowledge of root cause analysis, corrective action systems, and statistical problem solving.
• Familiarity with Lean Manufacturing and structured problem solving.
• Strong written and verbal communication skills.
• Ability to collaborate with operations, quality, engineering, and maintenance teams.

Responsibilities

• Develop, implement, and optimize thermal spray coating processes for aerospace gas turbine components.
• Support daily production activities by monitoring yield and reducing rework.
• Identify root causes and implement corrective actions for process and quality issues.
• Ensure thermal spray equipment and related process technologies are production-ready.
• Design and implement tooling, fixtures, gauging, and process improvements.
• Program and optimize 6-axis robotic systems used for thermal spray applications.
• Develop spray parameters for new coating materials and optimize existing processes.
• Develop and improve masking and surface preparation methods, including grit blasting.
• Create and maintain SOPs, work instructions, process specifications, calibration instructions, training materials, and quality records.
• Train operators and collaborate with maintenance teams on preventive maintenance programs.
• Participate in Kaizen, Lean, and continuous improvement initiatives.
• Apply Six Sigma and DMAIC methodologies to solve complex manufacturing problems.

Skills

Engineering experience

Aerospace MRO exposure

Root cause analysis

Lean manufacturing

Problem solving

Team collaboration

Communication skills

Education

Bachelor's degree in Engineering or related field

Tools

Siemens NX

6-axis robotics programming

Aerospace coating processes

Job description

Job Description

Travel: Occasional
Type: Full-time, Direct Hire
Relocation: Relocation assistance provided

About the Opportunity

A global engineering and manufacturing organization supporting the aerospace, energy, and defense industries is seeking a Thermal Spray Process Engineer to support the repair, overhaul, and manufacturing of critical gas turbine components.

This role offers the opportunity to work with advanced manufacturing technologies and contribute directly to product quality, turnaround time, delivery, and operational efficiency.

What You'll Do:

• Develop, implement, and optimize thermal spray coating processes for aerospace gas turbine components.
• Support daily production activities by monitoring yield, reducing rework, and improving process capability.
• Identify root causes and implement corrective actions for process and quality issues.
• Ensure thermal spray equipment and related process technologies are production-ready.
• Design and implement tooling, fixtures, gauging, and process improvements.
• Program and optimize 6-axis robotic systems used for thermal spray applications.
• Develop spray parameters for new coating materials and optimize existing processes.
• Develop and improve masking and surface preparation methods, including grit blasting.
• Create and maintain SOPs, work instructions, process specifications, calibration instructions, training materials, and quality records.
• Train operators and collaborate with maintenance teams on preventive maintenance programs.
• Participate in Kaizen, Lean, and continuous improvement initiatives.
• Apply Six Sigma and DMAIC methodologies to solve complex manufacturing problems.

What We're Looking For:

• Bachelor's degree in Engineering or a related scientific field such as Materials Science, Chemistry, or Physics.
• 3+ years of engineering experience in a manufacturing environment.
• Aerospace MRO or gas turbine experience preferred.
• Experience supporting manufacturing operations, process development, and continuous improvement.
• Knowledge of root cause analysis, corrective action systems, and statistical problem-solving.
• Familiarity with Lean Manufacturing and structured problem-solving methodologies.
• Strong written and verbal communication skills.
• Ability to collaborate effectively with operations, quality, engineering, and maintenance teams.

Preferred Experience:

• Thermal spray equipment and coating process development.
• Programming 6-axis robotic systems.
• 3D CAD experience, such as Siemens NX.
• Knowledge of APS, Dual Wire Arc Spray, and combustion spray processes.
• Aerospace masking and fixture design.
• Surface preparation and grit blasting requirements.
• Aerospace component repair, overhaul, or manufacturing.
• Lean Six Sigma Green Belt or Kaizen participation.
• Familiarity with aerospace quality systems and process control.

Work Environment:

This position combines office-based engineering work with regular activity on the production floor, in labs, and within repair operations.

The role requires the ability to stand, walk, bend, and reach for extended periods and occasionally lift up to 25 lbs. Appropriate PPE must be worn and all applicable safety procedures followed.

Some evening, weekend, or holiday hours may occasionally be required based on operational needs.

Additional Requirements:

Due to applicable government regulations, candidates must qualify as a U.S. person, including U.S. citizens, naturalized citizens, permanent residents, or approved asylees or refugees.

Employment is subject to applicable background and drug screening requirements.