Aerospace Quality Engineer

Expleo; Washington (District of Columbia); On-site; USD 69,000 - 115,000; Full time

Benefits offered by this job

Competitive compensation

Comprehensive benefits

Paid holidays and PTO

Career development

Job summary

Expleo Group USA is seeking experienced Aerospace Quality Engineers to support diverse aerospace programs, focusing on product quality assurance, inspection planning, FAI, supplier quality, and continuous improvement.

You will develop quality plans, ensure compliance with drawings and standards, and drive risk-based inspections across fabrication and assembly, coordinating with Engineering and Manufacturing to embed quality through the lifecycle.

Qualifications

• Bachelor's Degree in Engineering, Quality, Manufacturing, Aerospace, or related field or equivalent.
• 5+ years of aerospace quality engineering experience.
• Strong background in composite manufacturing quality and QA systems.
• Experience developing inspection plans and quality documentation.
• Experience executing First Article Inspections (FAI) and AS9102 requirements.

Responsibilities

• Develop and implement quality plans for aircraft modules, assemblies, and components.
• Ensure compliance with engineering drawings, specifications, and aerospace standards.
• Support production readiness with inspection and verification processes.
• Lead root cause analysis and corrective actions to reduce defects.
• Create and maintain FAI documentation and reports.
• Collaborate with Engineering, Manufacturing, and Program teams to embed quality throughout the lifecycle.

Skills

Quality engineering

Aerospace

Inspection planning

PFMEA

Root cause analysis

Education

Bachelor's degree in Engineering

Tools

AS9100

Job description

Overview

Expleo Group USA is seeking experienced Aerospace Quality Engineers to support our aerospace programs focused on product quality assurance, inspection planning, first article inspection (FAI), supplier quality, composite manufacturing quality, and continuous improvement initiatives.

Responsibilities:

Quality Planning & Product Assurance

• Develop and implement quality plans for aircraft modules, assemblies, and components.
• Ensure product compliance with engineering drawings, specifications, aerospace standards, and customer requirements.
• Support production readiness activities by establishing effective inspection and verification processes.
• Drive continuous improvement initiatives focused on product quality, process capability, defect reduction, and operational performance.
• Participate in design reviews, manufacturing reviews, and production readiness activities.
• Collaborate with Engineering, Manufacturing, and Program teams to ensure quality requirements are effectively integrated throughout the development and production lifecycle.
• Support implementation of risk-based quality strategies and process controls.

Inspection Planning & Quality Control

• Create and maintain detailed inspection plans for composite and structural aircraft components.
• Define critical characteristics, inspection requirements, acceptance criteria, and sampling methodologies.
• Collaborate with Engineering and Manufacturing teams to ensure inspection requirements align with product intent and manufacturing processes.
• Establish quality checkpoints throughout fabrication, assembly, integration, and production activities.
• Support implementation of risk-based inspection strategies and process control methodologies.
• Develop quality documentation and inspection standards to support production and customer requirements.

First Article Inspection (FAI)

• Create, coordinate, and execute First Article Inspections (FAI) in accordance with aerospace industry standards.
• Review engineering drawings, specifications, and Bills of Materials (BOMs) to verify all product requirements have been met.
• Prepare and maintain FAI documentation packages and inspection reports.
• Support corrective action activities resulting from nonconformances identified during FAI efforts.
• Ensure compliance with AS9102 and customer-specific First Article Inspection requirements.
• Coordinate cross-functional teams to successfully complete FAI activities and drive product readiness.

Composite Manufacturing Quality Support

• Provide quality engineering support for composite fabrication, bonding, assembly, curing, and structural integration processes.
• Evaluate manufacturing processes to identify quality risks and opportunities for improvement.
• Support root cause investigations and corrective action implementation related to production issues and nonconformances.
• Partner with Manufacturing Engineering teams to improve process capability, product quality, and first-pass yield.
• Assist in validation and implementation of new manufacturing processes and production changes.
• Support continuous improvement initiatives focused on quality performance and manufacturing excellence.

Supplier Quality & Development

• Collaborate with suppliers to establish effective quality controls, inspection requirements, and product acceptance criteria.
• Support supplier qualification activities, audits, and ongoing supplier development initiatives.
• Review supplier quality documentation, inspection plans, process controls, and corrective action responses.
• Assist in resolving supplier quality issues impacting production schedules, product conformity, or customer requirements.
• Evaluate supplier performance metrics and support supplier continuous improvement activities.
• Partner with Supply Chain and Manufacturing teams to ensure supplier quality performance supports program objectives.

Risk Management & Continuous Improvement

• Participate in PFMEA (Process Failure Mode and Effects Analysis) activities to identify and mitigate manufacturing and process risks.
• Support development of control plans and process controls based on PFMEA outputs.
• Lead root cause analysis and problem-solving activities utilizing: 8D Problem Solving, Root Cause Corrective Action (RCCA), 5 Why Analysis, Fishbone Diagrams, Statistical Process Control (SPC)
• Drive defect reduction, process improvement, and quality performance initiatives throughout production.
• Support quality KPI development, reporting, and trend analysis.
• Promote a culture of quality, accountability, and continuous improvement across the organization.

Qualifications:

• Bachelor's Degree in Engineering, Quality, Manufacturing, Aerospace, or a related technical discipline.
• Equivalent combination of education and relevant aerospace quality experience may be considered.
• 5+ years of quality engineering experience within aerospace, aviation, defense, or advanced manufacturing environments.
• Strong background supporting composite manufacturing processes and aerospace quality systems.
• Experience developing and maintaining inspection plans, quality documentation, and inspection methodologies.
• Demonstrated experience creating, executing, and supporting First Article Inspections (FAI).
• Strong understanding of blueprint reading, GD&T, engineering drawings, and technical specifications.
• Experience conducting root cause investigations and implementing corrective and preventive actions.
• Knowledge of aerospace quality standards, quality management systems, and manufacturing process controls.
• Proficiency utilizing quality metrics, inspection methodologies, and process improvement tools.
• Strong communication, collaboration, and stakeholder management skills.
• Experience working directly with suppliers to establish quality requirements and inspection methodologies.
• Experience defining supplier quality control plans and supplier quality processes.
• Hands-on experience with PFMEA development, facilitation, and implementation.
• Knowledge of AS9100, AS9102, and aerospace quality standards.
• Experience supporting composite aircraft structures, unmanned aerial systems (UAS), UAVs, or aerospace assemblies.
• Background in supplier audits, process audits, and supplier qualification activities.
• Certified Quality Engineer (CQE) certification or equivalent quality credential.
• Familiarity with statistical analysis, process capability studies, and quality improvement methodologies.
• Experience supporting Airbus aerospace programs or advanced aerospace manufacturing environments.

What We Offer

At Expleo Group USA, we value expertise, innovation, and collaboration. By joining our client's team, you'll support advanced aerospace programs while helping ensure the highest levels of product quality, regulatory compliance, and manufacturing excellence.

• Competitive Compensation - Up to $115,000 annually or $56/hourly. Final compensation will be determined based on the role, skill alignment, years of experience, and fair, market-based rates by geography.
• Comprehensive Benefits for You and Your Dependents - Extensive Medical Plans, Dental, Vision, HSA with company contribution, company-sponsored Life Insurance and Short/Long-Term Disability Insurance, a host of voluntary plans including legal, hospital, accident, pet wellness, and 401(k) with matching.
• Paid Holidays and Paid Time Off
• Career Development and Advancement - Expleo is a global company operating in 29 countries with a strong focus on professional development.
• Strong Team Culture - Collaborate with experienced professionals who value technical excellence, continuous improvement, quality, and teamwork.

This position may require access to information subject to U.S. export control regulations (e.g., ITAR/EAR). Employment is contingent upon the ability to obtain such access. Under these regulations, access may be limited to "U.S. Persons," including U.S. citizens, lawful permanent residents (green card holders), and individuals granted refugee or asylee status.

Expleo is a trusted partner for end-to-end, integrated engineering, quality services, and management consulting for digital transformation. We are a talent incubator. The time you spend at Expleo will turbocharge your career, allowing you to work on complex technical challenges, expand your skills, and participate in inspiring multidisciplinary collaborations. Whether working on advanced unmanned aircraft systems, next-generation aerospace manufacturing, or world-class quality programs, you'll have the opportunity to become a bolder version of yourself. Let's change the game together.

Expleo is an equal opportunity employer. We are committed to non-discrimination in all stages of the recruitment process, ensuring fair and unbiased hiring practices. We evaluate qualified applicants without regard to race, color, religion, sex (including pregnancy), sexual orientation, gender identity, national origin, age, disability, genetic information, or any other protected characteristic under applicable laws.