Ballistic Helmet Manufacturing Engineer I

Galvion; Newport (VT); On-site; USD 85,000 - 120,000; Full time

Job summary

Galvion is seeking a Manufacturing Engineer to lead and optimize the production of ballistic helmets within a regulated defense manufacturing environment. The role focuses on improving processes for advanced composites while ensuring ballistic integrity and high quality across production lines.

You will partner with R&D, support NPIs, and implement tooling and process controls to drive efficiency, yield, and regulatory compliance in a mission-critical setting.

Qualifications

• Bachelor’s degree in Mechanical, Materials, Industrial Engineering, or related field.
• 3-5+ years of manufacturing engineering experience in composites, defense, aerospace, or protective equipment.
• Hands-on experience with molding, pressing, or composite fabrication processes.
• Strong understanding of process control in safety-critical manufacturing.
• Experience with root cause analysis and continuous improvement methods.
• Automation & Controls; CAD experience preferred.

Responsibilities

• Develop, refine, and standardize manufacturing processes for ballistic helmet production (layup, molding/pressing, trimming, finishing, coating).
• Optimize cycle times, material utilization, and yield while maintaining ballistic integrity.
• Lead root cause analysis for defects such as delamination, voids, dimensional non-conformance, or coating failures.
• Define and control critical process parameters (temperature, pressure, cure time, consolidation).
• Partner with R&D on material selection, qualification, and process transfer.
• Support new product introduction (NPI) and transition from prototype to full-rate production.
• Design and implement tooling, fixtures, and work instructions for repeatable manufacturing.
• Balance throughput with strict compliance to ballistic performance standards.
• Implement SPC and process controls for safety-critical features.
• Support ballistic testing, lot acceptance, and failure investigations.
• Specify and improve equipment such as presses, ovens, automation equipment, and final assembly lines.
• Evaluate automation opportunities in material handling, cutting, painting and finishing operations.
• Improve equipment uptime and preventive maintenance strategies.
• Mentor technicians and junior engineers in best manufacturing practices.
• Contribute to capacity planning, cost reduction strategies, and long-term manufacturing roadmap.

Skills

Manufacturing engineering

Composites

Process control

Root cause analysis

Automation & controls

Leadership

Problem solving

Molding/pressing

Education

Bachelor's degree in Mechanical, Materials, Industrial Engineering

Tools

CAD

Job description

Galvion is seeking a Manufacturing Engineer to lead and optimize the production of ballistic helmets within a regulated defense manufacturing environment. The role focuses on improving processes for advanced composites while ensuring ballistic integrity and high quality across production lines.

You will partner with R&D, support NPIs, and implement tooling and process controls to drive efficiency, yield, and regulatory compliance in a mission-critical setting.