AFP Manufacturing Engineer II-Composites

Firefly Aerospace; Town of Texas (WI); On-site; USD 80,000 - 110,000; Full time

Benefits offered by this job

Generous health, dental, and vision plans

Educational/relocation reimbursement

Short-term disability

Flexible PTO options

Job summary

Firefly Aerospace in Wisconsin is seeking an AFP Manufacturing Engineer II to enhance automated composite layup processes. This position involves overseeing AFP programming using Ingersoll systems, developing ply programs, and troubleshooting process-related issues.

The ideal candidate will possess a Bachelor's degree in Mechanical Engineering, with over 5 years of aerospace manufacturing experience. Firefly offers excellent benefits, including health plans and flexible PTO.

Qualifications

• Bachelor's degree in Mechanical Engineering or a related Engineering field required.
• 5+ years experience in carbon fiber composite aerospace manufacturing.
• Experience with capital equipment implementation.

Responsibilities

• Oversee the development of AFP ply programs for composite parts.
• Translate engineering models into executable AFP paths.
• Collaborate with design engineering for manufacturability feedback.

Skills

Automated Fiber Placement experience

Excellent communication skills

CAD software proficiency

Analytical abilities

Problem-solving skills

Education

Bachelor's degree in Mechanical Engineering or related field

Master's degree (plus)

Tools

Ingersoll AFP systems

Vericut Composite Programming

Lean manufacturing Black Belt certification

Job description

AFP Manufacturing Engineer II – Composites

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.

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

• 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 an 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.