Aerospace Thermal Spray Process Engineer

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

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