Materials & Process Engineer (Composites/FAA)

All Aviation Jobs; San Jose (CA); On-site; USD 120,000 - 180,000; Full time

Job summary

All Aviation Jobs seeks a senior engineer to be the technical focal on airframe composites. You will lead development, qualification, and documentation for thermoset/thermoplastic systems, prepregs, resin infusion, and out-of-autoclave techniques.

Requires a Master’s in Materials, Chemical, or Mechanical Engineering, 8+ years in aerospace composites, FAA certification experience, NDT skills, and strong leadership, communication, and project management abilities.

Qualifications

• Master’s degree in a related field.
• 8+ years in aerospace composites and structures.
• Fatigue and damage-tolerance expertise.
• Material qualification, specs, and process development.
• Familiarity with FAA regulations, ACs, ASTM, MIL specs.
• Strong communication and project management.
• Experience with NDT methods is required.

Responsibilities

• Lead development and qualification of composite materials and structural processes.
• Author and maintain material specs, test plans, and procedures for certification.
• Collaborate with design, manufacturing, and certification teams to meet requirements.
• Support failure analysis and corrective actions for composite structures.
• Interface with FAA, DERs, and regulatory bodies for certification.

Skills

Leadership in qualification

Strong communication

Project management

NDT experience

Aerospace composites knowledge

Education

Master’s degree in Materials, Chemical, or Mechanical Engineering

Job description

• Serve as the technical focal and authority on the development of the airframe, including SME support in composite materials and processes for thermoset and thermoplastic systems, prepregs, resin infusion, and out-of-autoclave techniques.
• Lead the development and qualification of composite materials and structural processes, including material allowable, process specifications, and design guidelines.
• Author and maintain material and process specifications, including test plans, qualification procedures, and documentation for FAA certification.
• Collaborate with design, manufacturing, and certification teams to ensure composite structures meet strength, stiffness, fatigue, and damage tolerance requirements.
• Support failure analysis, root cause investigations, and corrective actions related to composite structures.
• Interface with FAA, DERs, and other regulatory bodies to support certification and conformity efforts. What You Need :-
• Master’s degree in Materials, Chemical, or Mechanical Engineering, or a related field.
• Minimum 8 years of experience in aerospace composite materials and structures, with a strong track record of leadership in material qualification and certification.
• Proven expertise in composite behavior, including fatigue, damage tolerance, environmental effects, and repairability.
• Extensive experience with material qualification, specification creation, and process development for composite airframes.
• Familiarity with FAA regulations, Advisory Circulars, ASTM standards, and MIL specifications.
• Strong communication and project management skills.
• Experience with non-destructive testing (NDT) methods is required.