Manufacturing Engineer I — Ballistic Helmet & Composites

Galvion LTD

Newport (VT)

On-site

USD 90,000 - 115,000

Full time

9 days ago

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Job summary

Galvion is seeking a Manufacturing Engineer to lead the production of ballistic helmets and protective systems in a defense manufacturing environment. You will refine processes for composites, ensure ballistic performance, and drive efficiency while upholding strict quality and compliance standards.

You will collaborate with R&D for material selection, support NPI, and implement tooling and controls to enable repeatable manufacturing.

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.
CAD Experience Preferred.
PLC Logic Understanding.
Deep process ownership mindset in a safety-critical environment.
Ability to balance throughput, cost, and uncompromising quality.
Strong analytical and problem-solving capability (especially with materials/process interactions).
Leadership and influence across production teams.

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.