Machining Manufacturing Engineer

Butler America Aerospace L.L.C.; Culpeper (VA); On-site; USD 83,000 - 96,000; Full time

Benefits offered by this job

401K

Medical insurance

Dental insurance

Vision insurance

Sick time as applicable to state law

Job summary

Butler America Aerospace, LLC is seeking a Manufacturing Engineer (Machining) to support energetic and non-energetic machining operations in Culpeper, VA. The role includes CNC programming, DFMs, and driving process improvements across multiple programs.

Reporting to the Manufacturing Engineering Manager, you will lead high-impact projects, mentor junior engineers, and ensure safety, quality, and regulatory compliance in collaboration with operations, design engineering, and program management.

Qualifications

• Must be able to obtain and maintain a U.S. Security Clearance.
• Bachelor's degree or higher in a related engineering discipline with relevant experience.
• Experience with energetic materials machining and manufacturing processes is a plus.

Responsibilities

• Apply advanced machining and fabrication principles to energetic and non-energetic operations.
• CNC programming and operation; DFMs and process documentation.
• Lead improvement projects with measurable impact; mentor junior staff.

Skills

Security clearance eligibility

Education

Bachelor's degree in Mechanical, Aerospace, Chemical Engineering, or closely related field

Graduate degree in Mechanical, Aerospace, Chemical Engineering or closely related field

10+ years of related engineering experience in lieu of a degree

Job description

Manufacturing Engineer (Machining)

Location: Culpeper, VA

Job ID: #73035

Pay Range: $ 60 - 70

Seeking an experienced Senior Specialist, Manufacturing Engineer to join our Missile Solutions Segment at our Orange, VA facility - our center of excellence for Solid Rocket Motor Propulsion, Energetics development, and high-complexity production programs. Nestled in the beautiful, rural Orange County countryside, this site offers a unique opportunity to work on cutting-edge defense programs in a collaborative and mission-driven environment.

U.S. Citizenship only, no dual citizenship

Reporting to the Manager of Manufacturing Engineering, this position operates within a matrixed organization alongside operations, quality engineering, design engineering, and program management. The Senior Specialist will focus on improving, automating, and growing existing production lines, with a strong emphasis on energetic machining operations, machine shop processes, and manufacturing excellence. This role will lead significant improvement projects with measurable impact across multiple programs, while also mentoring and developing junior engineering staff.

Key Responsibilities

• Apply advanced knowledge of machining and fabrication principles to support and improve energetic and non-energetic manufacturing operations, including:
• CNC programming and operation
• Design for Machining (DFM) principles
• Precision machining of energetic components and assemblies
• Machine shop equipment operation, setup, and optimization
• Lead and support energetic assembly, machining, and manufacturing operations, ensuring strict adherence to safety protocols and regulatory requirements
• Drive modernization and automation of production facilities, including the evaluation and integration of new machining technologies and process equipment
• Demonstrate process ownership of established manufacturing activities by utilizing systematic tools to determine root cause, implement improvements, and ensure conformance to safety and quality standards
• Develop and maintain detailed process documentation including:
• Process Failure Mode and Effects Analyses (PFMEAs)
• Manufacturing Bills of Materials (MBOMs)
• Process Hazard Analyses (PHAs)
• Job Safety Analyses (JSAs)
• Detailed work instructions and process sheets based on technical drawings and specifications
• Lead defect identification, root cause investigations, and resolution activities to reduce Cost of Poor Quality (CoPQ)
• Monitor and maintain Statistical Process Control (SPC) programs to ensure process stability and capability
• Support tooling development and design reviews, including implementation into manufacturing processes and associated safety reviews
• Direct and mentor lower-level manufacturing engineering staff, providing technical guidance and supporting the knowledge development of novice engineers
• Collaborate cross-functionally with quality, design engineering, operations, and program management to resolve manufacturing challenges and support program objectives
• Travel up to 5% of the time as required to support program needs

Skills: Required Qualifications

• Bachelor's degree in Mechanical, Aerospace, Chemical Engineering, or a closely related engineering discipline with a minimum of 6 years of prior relevant engineering experience
• OR Graduate degree in Mechanical, Aerospace, Chemical Engineering, or a closely related discipline with a minimum of 4 years of prior related experience
• OR in lieu of a degree, a minimum of 10 years of prior related engineering experience
• Must be able to obtain and maintain a U.S. Security Clearance

Preferred Qualifications

• Hands-on experience with energetic materials machining and assembly operations
• Strong proficiency in CNC programming, setup, and operation within a precision machining environment
• Experience with machine shop tools and fabrication equipment including mills, lathes, grinders, and related tooling
• Demonstrated experience interpreting and working from technical drawings, engineering specifications, and GD&T requirements
• Proven track record of leading high-impact manufacturing improvement projects with measurable results
• Experience with automation integration in a machining or manufacturing environment
• Familiarity with DoD 4145 standards and energetic materials safety requirements
• Strong problem-solving skills with experience applying structured root cause analysis methodologies (e.g., 8D, 5-Why, Fishbone)
• Excellent written and verbal communication skills with the ability to present technical information to diverse audiences
• Experience with Lean Manufacturing, Six Sigma, or other continuous improvement frameworks
• Familiarity with ERP/MES systems and manufacturing data analysis tools

Education:

• Bachelor's degree in Mechanical, Aerospace, Chemical Engineering, or a closely related engineering discipline with a minimum of 6 years of prior relevant engineering experience
• OR Graduate degree in Mechanical, Aerospace, Chemical Engineering, or a closely related discipline with a minimum of 4 years of prior related experience
• OR in lieu of a degree, a minimum of 10 years of prior related engineering experience

Benefits

• 401K, medical, dental, and vision, sick time as applicable to state law

Butler America Aerospace, LLC. is an equal opportunity employer. Butler evaluates applicants without regard to race, color, religion, sex, age, national origin, disability, veteran status, genetic information and other legally protected characteristics. The Butler America Aerospace, LLC. EEO Policy Statement and "Know Your Rights" Poster is available here: Applicant and Employee Notices.

Butler America Aerospace, LLC. is committed to working with and providing reasonable accommodations to individuals with disabilities. If you need a reasonable accommodation because of a disability for any part of the employment process, please contact the Human Resources Department at [e-mail].