Composites Automated Fiber Placement Programmer

Blue Origin; Merritt Island (FL); On-site; USD 90,000 - 130,000; Full time

Job summary

Blue Origin is seeking a Composite Manufacturing Engineer specializing in Automated Fiber Placement to support development, industrialization, and production of flight-critical composite structures for next-generation launch vehicles and spacecraft.

This role will develop, qualify, optimize, and sustain AFP processes while collaborating with production technicians, design, quality, and operations leadership. Level may be Engineer I–III based on experience.

Qualifications

• Bachelor’s degree in a relevant engineering discipline.
• Experience in composite fabrication and automated manufacturing.
• Ability to interpret engineering drawings, specifications, ply definitions, and GD&T.
• Experience troubleshooting manufacturing processes using data-driven root-cause methods.
• Experience supporting flight-critical aerospace hardware.

Responsibilities

• Develop, qualify, document, and sustain Automated Fiber Placement processes for aerospace composite structures.
• Create and optimize ply books, layup sequences, tow paths, course boundaries, steering strategies, and deposition rates.
• Program, simulate, verify, and release AFP programs using Vericut or offline programming software.
• Troubleshoot AFP equipment, Siemens motion systems, robotic cells, CNC interfaces, PLC logic, HMIs, sensors.
• Establish process parameters and acceptance criteria for laminate quality, dimensional accuracy, repeatability, and throughput.
• Support composite manufacturing processes including hand layup, vacuum bagging, autoclave curing, and related steps.
• Integrate probing and in-process metrology for setup and calibration.
• Lead root-cause investigations using 5 Whys, fishbone, fault-tree, and 8D methods.

Skills

Cross-functional communication

Analytical skills

Troubleshooting

Hands-on manufacturing

Education

Bachelor’s degree in mechanical, aerospace, materials, manufacturing, or related engineering

Tools

Vericut Composite Programming

CATIA

Siemens NX

Fibersim

Creo

Siemens SINUMERIK 840D

Job description

At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight!

This role is part of Blue Origin Operations, which is comprised of Integrated Supply Chain, Test Operations, Safety, Quality, and Mission Assurance. This includes Manufacturing and Supply Chain support across all Blue Origin facilities.

Composite Manufacturing Engineer

Automated Fiber Placement

Blue Origin is seeking a Composite Manufacturing Engineer specializing in Automated Fiber Placement to support the development, industrialization, and production of flight-critical composite structures for next-generation launch vehicles and spacecraft.

This position will develop, qualify, optimize, and sustain automated composite manufacturing processes while working directly with production technicians, design engineers, quality engineers, materials engineers, tooling teams, equipment suppliers, and operations leadership.

The successful candidate will combine practical composite manufacturing knowledge with automated equipment, process-control, and production-support experience. The position may be filled at the Engineer I, Engineer II, or Engineer III level based on the candidate’s education, experience, technical depth, and demonstrated level of responsibility.

Responsibilities

• Develop, qualify, document, and sustain Automated Fiber Placement processes for aerospace composite structures.
• Create and optimize ply books, layup sequences, tow paths, course boundaries, steering strategies, compaction parameters, tow-drop locations, and deposition rates.
• Program, simulate, verify, and release AFP programs using Vericut Composite Programming or equivalent offline programming software.
• Troubleshoot AFP equipment, Siemens-controlled motion systems, robotic cells, CNC interfaces, PLC logic, HMIs, sensors, and supporting industrial automation.
• Establish process parameters and acceptance criteria for laminate quality, dimensional accuracy, repeatability, and production throughput.
• Support composite manufacturing processes including hand layup, automated tape laying, vacuum bagging, autoclave curing, out-of-autoclave processing, composite assembly, trimming, drilling, and machining.
• Integrate probing, laser measurement, touch-probe, and in-process metrology systems to support equipment setup, calibration, alignment, and process verification.
• Support equipment installation, commissioning, Factory Acceptance Testing, Site Acceptance Testing, capability qualification, and production-readiness reviews.
• Investigate defects such as gaps, overlaps, wrinkles, bridging, tow-placement errors, foreign-object debris, porosity, delamination, and dimensional variation.
• Lead structured root-cause and corrective‑action investigations using methods such as 5 Whys, fishbone analysis, fault-tree analysis, and 8D.
• Perform statistical process control, measurement-system analysis, capability studies, design of experiments, and process‑performance evaluations.
• Develop and maintain manufacturing plans, work instructions, standard operating procedures, process specifications, PFMEAs, control plans, inspection requirements, and equipment setup documentation.
• Collaborate with design and materials engineering to evaluate manufacturability, material selection, laminate design, tooling concepts, cure cycles, and production risks.
• Support configuration control and implementation of engineering changes affecting tooling, equipment, software, programs, materials, and manufacturing processes.
• Improve cycle time, first-pass yield, equipment availability, overall equipment effectiveness, scrap, rework, and production labor efficiency.
• Provide hands‑on production support and technical direction to technicians, operators, programmers, and maintenance personnel.
• Mentor less‑experienced engineers and technicians as appropriate for the assigned position level.

Minimum Qualifications

• Bachelor’s degree in mechanical, aerospace, materials, manufacturing, industrial engineering, or a related technical discipline.
• Experience supporting composite fabrication, automated manufacturing, robotic manufacturing, CNC equipment, or another closely related aerospace production environment.
• Working knowledge of composite materials and processes, including prepreg handling, layup, debulk, vacuum bagging, curing, laminate defects, and material‑storage controls.
• Ability to interpret engineering drawings, specifications, ply definitions, manufacturing plans, and geometric dimensioning and tolerancing requirements.
• Experience developing controlled manufacturing documentation such as work instructions, process specifications, manufacturing plans, or standard operating procedures.
• Experience troubleshooting manufacturing processes using data‑driven root‑cause and corrective‑action methods.
• Ability to work directly with production personnel in a hands‑on manufacturing environment.
• Strong written, verbal, analytical, and cross‑functional communication skills.
• Ability to support flight‑critical hardware in a fast‑paced production and development environment.

Desired Qualifications

• Direct experience programming and developing Automated Fiber Placement processes.
• Experience with AFP equipment manufactured by Ingersoll Machine Tools, MTorres, Coriolis Composites, Electro impact or similar equipment suppliers.
• Experience with Vericut Composite Programming, CATIA, Siemens NX, Fibersim, Creo, or comparable composite CAD/CAM software.
• Experience with Siemens SINUMERIK 840D, Siemens PLCs, Siemens motion‑control systems, or comparable industrial control platforms.
• Experience with FANUC, ABB, KUKA, or other industrial robotic systems.
• Experience with Renishaw probing, laser trackers, photogrammetry, CMM inspection, or other precision‑metrology systems.
• Experience developing and validating autoclave and out‑of‑autoclave cure cycles.
• Understanding of laminate theory, composite material behavior, cure kinetics, tack, drape, compaction, and defect‑formation mechanisms.
• Experience with CNC trimming, drilling, routing, machining, or assembly of composite structures.
• Experience conducting PFMEAs, design of experiments, statistical process control, measurement‑system analyses, and Cp/Cpk studies.
• Experience with manufacturing execution systems, equipment‑data collection, machine connectivity, digital work instructions, or predictive‑maintenance systems.
• Experience supporting New Product Introduction, production ramp‑up, or transition from development into rate production.
• Knowledge of AS9100, aerospace configuration control, process validation, and manufacturing requirements for flight‑critical hardware.
• Lean Six Sigma Green Belt, Black Belt, or equivalent continuous‑improvement experience.

If you are passionate about advanced composite manufacturing, automation, and helping build the future of spaceflight, we encourage you to join Blue Origin and contribute to the next generation of reusable launch systems and spacecraft.

Culture Statement

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