AFP Manufacturing Engineer II-Composites

Firefly Aerospace; Texas; On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Health, dental and vision plans

Educational/relocation reimbursement

Short term disability

Flexible PTO

Job summary

Firefly Aerospace is seeking an AFP Manufacturing Engineer II-Composites to develop and optimize automated fiber placement processes for aerospace components. You will generate precise ply programs, improve part quality, reduce cycle times, and troubleshoot AFP issues in collaboration with design, NC programming, operations, quality, and maintenance teams.

The role requires creating reliable AFP programs, validating with simulations, and supporting process improvements in a fast-paced aerospace

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• 5+ years in carbon fiber composite aerospace manufacturing.
• Automated Fiber Placement experience.
• Proficiency in CAD and AFP Programming.
• Six Sigma or Lean manufacturing Black Belt certification.

Responsibilities

• Oversee AFP ply programs for composite parts using Ingersoll Gen2, Vericut programming tools, ensuring conformance to design intent.
• Translate engineering models, ply books, and lamination schedules into AFP paths with accurate fiber orientation and coverage.
• Support Ingersoll machine setup, calibration, and laser alignment for production runs.
• Analyze and optimize machine pathing to minimize defects and improve efficiency.
• Review AFP programs with simulations and dry runs with operators during start-ups.
• Collaborate with design engineering for design for manufacturability feedback.
• Investigate and resolve process-related issues with maintenance and support teams.
• Develop standard work instructions and AFP best practices.

Skills

Automated Fiber Placement experience

Cross-functional collaboration

Problem solving and analytics

Six Sigma/Lean Black Belt

Strong communication

Education

Bachelor's degree in Mechanical Engineering or related field

Master's degree (a plus)

Tools

CAD software

AFP programming

Ingersoll AFP Gen2 & Vericut tools

Job description

AFP Manufacturing Engineer II-Composites

Firefly Aerospace is a space and defense technology company on a mission to reliably and repeatedly launch, land, and operate space systems from Earth to the Moon and beyond. As the partner of choice for critical space missions, Firefly is the first commercial company to launch a satellite to orbit with 24-hour notice and the first company to achieve a successful Moon landing. Headquartered in north Austin, Texas, Firefly is looking for passionate, hardworking innovators to join our team and help fuel our successful trajectory into space.

SUMMARY

The Automated Fiber Placement (AFP) Engineer is responsible for the development, and optimization of automated composite layup processes and overseeing the AFP programming process using Ingersoll AFP systems. This role supports production and engineering by generating precise ply programs, improving part quality, reducing cycle time, and troubleshooting AFP-related issues in the manufacture of complex aerospace components. The AFP Engineer works closely with design engineering, NC programming, operations, quality, and maintenance teams.

The following essential job functions are performed as an Automated Fiber Placement Engineer:

RESPONSIBILITIES

• Oversee the development AFP ply programs for composite parts using Ingersoll Gen2, (VCP) Vericut Composite Programming, and (VCS) Vericut Composite Simulation programming tools and simulation software, ensuring conformance to design intent and manufacturing constraints
• Translate engineering models, ply books, and lamination schedules into executable AFP paths with accurate fiber orientation, coverage, and boundaries
• Support Ingersoll machine setup, calibration, and laser alignment for first article and repeatable production runs
• Analyze and optimize machine pathing to minimize defects (e.g., gaps, overlaps, tow steering errors), improve machine efficiency, and extend tool life
• Review and validate AFP programs with simulations and dry runs, working alongside operators during production start-ups
• Collaborate with design engineering to provide design for manufacturability (DFM) feedback for composite parts intended for AFP
• Investigate and resolve machine and process-related issues, working cross-functionally with maintenance and Ingersoll technical support as needed
• Participate in tooling design reviews to ensure compatibility with AFP head dimensions, access, and laser projection systems
• Implement and document process improvements, material usage reductions, and automation enhancements
• Work with facilities team to enhance critical spares documentation and write PM plans.
• Develop and maintain standard work instructions, AFP best practices, and process documentation
• Support audits, root cause investigations, and corrective actions involving AFP-manufactured parts
• Maintains composure under pressure while successfully managing multiple deadlines
• Being at work on time and maintaining good attendance is a condition of employment and is an essential function of the job
• Must have excellent communication skills, both verbal and written in the English language

QUALIFICATIONS

Required

• Bachelor's degree in Mechanical Engineering or a related Engineering field.
• 5 years experience in carbon fiber composite aerospace manufacturing
• Strong technical aptitude and ability to quickly become an expert on complex hardware.
• Automated Fiber Placement experience
• Experience with interrogating machine efficiency and implementing process improvements to reduce time and waste.
• Proficiency in CAD software and AFP Programming.
• Excellent communication skills and ability to collaborate effectively with cross-functional teams.
• Demonstrated track record of driving process improvements and delivering results in a fast-paced environment.
• High level of initiative, self-motivation, and ability to thrive in a dynamic and challenging work environment.
• Excellent problem-solving and analytical abilities.
• 5+ years working in a aerospace manufacturing or engineering environment with a bachelor’s degree in mechanical, aerospace, or similar area.
• Experience with capital equipment implementation.
• Master's degree is a plus.
• Six Sigma or Lean manufacturing Black Belt certification

Firefly offers outstanding benefits for our employees, including generous health, dental and vision plans with low plan deductibles, parental leave, educational/relocation reimbursement, short term disability, and flexible PTO options.

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Firefly Aerospace, Inc. is an Equal Opportunity Employer; employment with Firefly is governed based on merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.