Composites Manufacturing Engineer II

Firefly Aerospace; Town of Texas (WI); On-site; USD 95,000 - 140,000; Full time

Benefits offered by this job

Health, dental, and vision plans

Relocation reimbursement

Flexible PTO options

Educational reimbursement

Job summary

Firefly Aerospace is seeking a Manufacturing Engineer to join the Structures Department to help develop tooling and fixtures for the world’s largest liquid-fueled all-composite rocket and implement full-rate production on current programs.

You will lead tooling and fixturing design, drive continuous improvements, optimize processes, and provide technical expertise to enhance our production capabilities while collaborating with design, manufacturing, and quality teams to meet schedule and quality

Qualifications

• Bachelor's in Mechanical Engineering or related field.
• 5 years in carbon fiber composite aerospace manufacturing.
• Strong technical aptitude and ability to learn complex hardware quickly.
• Proficiency in CAD software for tooling and fixturing.
• Excellent collaboration and communication across teams.
• Track record of driving process improvements in a fast-paced environment.
• 7+ years in aerospace manufacturing/engineering; Master’s a plus.
• Automated Fiber Placement experience; quick-turn composite tooling design.
• Six Sigma or Lean manufacturing Black Belt certification.

Responsibilities

• Lead design and development of tooling, fixtures, and production equipment for aerospace composites.
• Optimize manufacturing processes to reduce cycle times and costs.
• Own hardware development and production processes, meeting schedules.
• Develop and implement tooling/fixturing to enhance efficiency and quality.
• Act as primary expert for part fabrication knowledge and guidance.
• Support floor operations and drive continuous improvement with cross-functional teams.
• Create detailed work instructions to standardize processes and ensure quality.
• Lead root-cause analysis and corrective actions for nonconformances.
• Collaborate with design, manufacturing, and quality teams for smooth production integration.
• Manage and oversee manufacturing programs to meet quality, cost, and schedule.
• Identify and address production challenges to ensure timely delivery.
• Implement and maintain rigorous quality controls per industry standards.
• Identify cost-saving opportunities and participate in cost-reduction initiatives.
• Champion Lean and Six Sigma practices across manufacturing processes.
• Mentor junior engineers.

Skills

Carbon fiber composites

CAD software

Communication

Process improvements

Self-motivation

Problem-solving

Aerospace industry experience

Automated Fiber Placement

Composite tooling

Six Sigma

Education

Bachelor's degree in Mechanical Engineering

Master's degree

Tools

CAD software

Six Sigma tools

Lean manufacturing

Job description

Career Opportunities with Firefly Aerospace

Come be a part of the 21 st Century Space Race!

Careers At Firefly Aerospace

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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

We are seeking a highly motivated and dedicated Manufacturing Engineer to join our Structures Department. As part of a small, fast-paced, and passionate team you will be instrumental developing the world’s largest liquid fueled all composite rocket and implementing full rate production on our current vehicle and programs.

You will be responsible for developing tooling and fixtures for development programs as well as production programs, driving continuous improvement initiatives, optimizing processes, developing brand new processes, and providing technical expertise to enhance our production capabilities. This role will give you a wide variety of opportunities. This position requires a strong background in engineering, extensive experience with practical problem solving and the ability to learn quickly.

RESPONSIBILITIES

• Lead the design and development of tooling, fixtures, and production equipment necessary for the manufacturing of aerospace composite components. This includes selecting appropriate materials and manufacturing processes to meet specific aerospace industry standards.
• Continuously evaluate and enhance manufacturing processes, tooling, and fixtures to optimize efficiency, quality, and cost-effectiveness. Implement improvements to increase production capacity and reduce cycle times.
• Take ownership of hardware development and production processes, ensuring adherence to schedules and driving continuous improvements.
• Develop and implement innovative solutions for tooling and fixturing to enhance manufacturing efficiency and quality.
• Act as the primary point of contact for all aspects related to part expertise, including understanding intricacies of the hardware and providing guidance on its fabrication.
• Support manufacturing floor operations by actively engaging with production teams to identify areas for improvement and implementing necessary changes.
• Create detailed work instructions and procedures to standardize manufacturing processes and ensure consistency in product quality.
• Lead the resolution of nonconformance issues by assessing root causes and implementing corrective actions to bring parts back into compliance.
• Demonstrate exceptional problem-solving skills and a proactive approach to addressing challenges in a fast-paced environment.
• Work closely with cross-functional teams, including design, manufacturing, and quality, to ensure the seamless integration into the production process.
• Manage and oversee manufacturing programs, ensuring they meet quality, cost, and schedule requirements.
• Identify and address production challenges, implementing effective solutions to ensure the timely delivery of high-quality aerospace components.
• Implement and maintain rigorous quality control measures to meet industry standards and customer expectations.
• Identify cost-saving opportunities and participate in cost reduction initiatives while maintaining product integrity.
• Champion a culture of continuous improvement, driving Lean and Six Sigma principles throughout the manufacturing process.
• Mentor less experienced engineers

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.
• Proficiency in CAD software for developing tooling and fixturing designs.
• 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.
• 7+ years working in a aerospace manufacturing or engineering environment with a bachelor’s degree in mechanical, aerospace, or similar area.
• Master's degree is a plus.
• Automated Fiber Placement experience
• Quick-turn custom composite tooling design and fabrication
• 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.