Manufacturing Engineer IV

Galvion LTD; Newport (VT); On-site; USD 110,000 - 140,000; Full time

Job summary

Galvion LTD is seeking a Manufacturing Engineer IV to lead and optimize ballistic helmet production in a defense manufacturing environment. You will refine processes for layup, molding/pressing, trimming, finishing, and coating while ensuring quality and ballistic integrity.

The role emphasizes cross-functional collaboration with R&D, starting from prototype to full-rate production, and requires deep expertise in composites, process control, and safety standards.

Qualifications

• Bachelor's degree in Mechanical, Materials, Industrial Engineering, or related field.
• 8-12+ 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 that applies to 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

Skills

Molding & pressing

Composite fabrication

Root cause analysis

Continuous improvement

Process control

CAD experience

PLC understanding

Safety-critical mindset

Leadership

Education

Bachelor's degree in Mechanical/Materials/Industrial Eng

Tools

CAD software

PLC programming

Job description

THE COMPANY

Galvion is a global defense technology leader specializing in advanced protective solutions and intelligent power systems for military and tactical operations worldwide. We designs, develops, and manufactures ballistic helmets and data management solutions for the modern battlefield. Galvion emphasizes innovation, collaboration, and forward-thinking design to meet the evolving needs of the modern world.

ABOUT THE OPPORTUNITY

The Manufacturing Engineer IV is responsible for leading and optimizing the production of ballistic helmets and advanced protective systems in a regulated defense manufacturing environment. This role focuses on improving manufacturing processes for advanced composite materials, ensuring consistent ballistic performance, increasing production efficiency, and maintaining strict quality and compliance standards. The position supports production scaling, continuous improvement initiatives, cross-functional collaboration, and the delivery of mission-critical protective equipment for military and law enforcement applications.

WHAT YOU'LL BE DOING

• 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

WHAT YOU'LL BRING

• Bachelor's degree in Mechanical, Materials, Industrial Engineering, or related field
• 8-12+ 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

Preferred

• Experience with ballistic materials (aramids, UHMWPE, hybrid composites)
• Familiarity with defense contracting requirements and documentation
• Lean / Six Sigma certification (Green or Black Belt)

WHY JOIN GALVION?

At Galvion, innovation, collaboration, and purpose drive everything we do. You'll work alongside talented professionals dedicated to developing advanced protective systems that help safeguard those who serve. We offer challenging work, opportunities for professional growth, and the chance to contribute to products that make a real-world difference.

If you're passionate about excellence engineering and want to help shape the future of military protection, we'd love to hear from you.

Galvion provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, gender, sexual orientation, gender identity or expression, national origin, age, disability, genetic information, marital status, amnesty, or status as a covered veteran in accordance with applicable federal, state and local laws. Galvion complies with applicable state and local laws governing non-discrimination in employment in every location in which the company has facilities. This policy applies to all terms and conditions of employment, including, but not limited to, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.