Carbon Fiber Composites Design & Process Development Engineer

Edgewater Technical Associates, LLC; Oak Ridge (TN); On-site; USD 90,000 - 120,000; Full time

Job summary

Edgewater Technical Associates, LLC is looking for a Carbon Fiber Composites Design & Process Development Engineer in Oak Ridge, TN. This role requires expertise in the design, analysis, and manufacturing of carbon fiber composite parts, with a focus on driving R&D and production initiatives.

The ideal candidate will hold a Bachelor’s degree in Materials Science or Mechanical Engineering, possess a minimum of 10 years' experience, and demonstrate strong skills in structural analysis using ANSYS or similar tools. Excellent communication and teamwork abilities are also essential.

Qualifications

• Minimum of 10 years’ experience with a Bachelor's degree, or a Master's degree with at least 5 years’ experience.
• Demonstrated expertise in carbon fiber composite design and mechanics of composite materials.
• Proven experience in structural analysis using simulation tools.

Responsibilities

• Lead design and development of carbon fiber composite parts.
• Perform structural analysis using advanced simulation tools.
• Develop and optimize composite manufacturing processes.

Skills

Carbon fiber composite design

Structural analysis

Problem-solving skills

Teamwork

Education

Bachelor’s degree in Materials Science or Mechanical Engineering

Tools

ANSYS

CAD/CAM software

Job description

Edgewater Technical Associates is seeking qualified candidates for a Carbon Fiber Composites Design & Process Development Engineer opportunity in Oak Ridge, TN.

Position Summary

We are seeking a highly motivated and experienced Carbon Fiber Composites Design and Process Development Engineer to lead the design, analysis, and manufacturing process improvements of carbon fiber composite parts and vessels. In this role, you will drive both research and high-volume production initiatives, bridging the gap between innovative concept development and efficient manufacturing for advanced composite systems.

Key Responsibilities

• Design and develop carbon fiber composite parts and vessels, ensuring optimal strength-to-weight ratios and durability.
• Perform mechanics of materials and structural analysis of composite systems using ANSYS or other advanced simulation tools.
• Experience in translating layup design into bulk anisotropic composite property estimates.
• Develop, validate, and optimize composite manufacturing processes—from tooling and fixture design to layup, curing, and machining—to meet rigorous quality and throughput goals.
• Lead R&D initiatives as well as high-volume production efforts, seamlessly transitioning concepts to production-scale applications.
• Collaborate with cross-functional teams including design, materials science, quality, and production to select composite systems and validate performance.
• Create detailed work instructions, process documentation, and quality protocols that ensure consistency and adherence to industry standards.
• Identify opportunities for continuous improvement, applying lean manufacturing and statistical process control methodologies.
• Mentor junior engineers and technicians, and provide technical leadership during process troubleshooting and corrective action implementation.

Required Qualifications

• Education: Bachelor’s degree (BS) in Materials Science, Mechanical Engineering, or a related field with a minimum of 10 years’ experience, or a Master’s degree (MS) or higher with at least 5 years’ relevant experience.
• Demonstrated expertise in carbon fiber composite design and the mechanics of composite materials.
• Proven experience in structural analysis, particularly with simulation tools such as ANSYS or equivalent.
• Extensive background in developing and improving composite manufacturing processes in both R&D and high throughput production environments.
• Excellent communication, teamwork, and problem-solving skills.

Preferred Qualifications

• Advanced understanding of composite processing techniques (e.g., autoclave curing, resin infusion, precision layup) and quality assurance methodologies.
• Experience with CAD/CAM software for tooling and fixture development.
• Familiarity with lean manufacturing principles or Six Sigma practices.
• A proactive, hands-on approach with strong analytical and technical aptitude.

Other Job Requirements

• United States Citizenship
• Ability to obtain and maintain required DOE and/or NRC security access authorization.

Equal Opportunity Employer

Edgewater is an equal opportunity employer and all qualified applicants will be considered for employment without regard to race, color, religion, sex, national origin, protected veterans, or individuals with disabilities in accordance with EO 14173.