R&D Manufacturing Lead - Advanced Composites

Kensington360; Vermont; On-site; USD 140,000 - 200,000; Full time

Job summary

Kensington360 is seeking an experienced R&D Manufacturing Engineering Lead for Advanced Composites to drive development of next-generation composite manufacturing technologies for aerospace and eVTOL platforms.

The role focuses on composite process development, new materials, manufacturing optimization and scaling R&D technologies into production while leading a growing team of manufacturing engineers. Strong emphasis on DFM, DFA, Lean and Six Sigma methodologies.

Qualifications

• 8+ years of manufacturing engineering experience including composite R&D or NPI.
• Experience with multiple composite manufacturing processes (AFP, RTM, ATL, autoclave, press forming).
• Proven track record scaling processes from R&D to production.

Responsibilities

• Develop and implement advanced composite manufacturing technologies.
• Lead R&D projects on new composite materials and methods.
• Develop scalable processes for aerospace composite structures (wings, fuselage).
• Transition technologies from prototype to full production (NPI).
• Mentor and lead a team of manufacturing engineers (≈3 direct reports).
• Apply Lean, Six Sigma, DOE and SPC to optimize performance.
• Support facility expansion, equipment selection and commissioning.
• Create DFM guidelines and process control standards.

Skills

Composite processes

Lean manufacturing

Six Sigma

DOE

SPC

DFM

DFA

GD&T

Leadership

Project management

Education

Bachelor's degree in Manufacturing/Mechanical/Aerospace Engineering

Advanced degree in Materials/Manufacturing Engineering

Tools

CATIA

SolidWorks

Manufacturing systems software

Job description

R&D Manufacturing Engineering Lead – Advanced Composites

Industry: Aerospace | Advanced Manufacturing | eVTOL

Employment Type: Full-Time

About the Role

Kensington360 is partnering with an innovative aerospace manufacturer to recruit an experienced R&D Manufacturing Engineering Lead – Advanced Composites.

This position will lead the development and implementation of advanced composite manufacturing technologies for next-generation aircraft, including eVTOL platforms.

The successful candidate will focus on composite process development, new materials, manufacturing optimisation and scaling R&D technologies into production, while leading a growing team of manufacturing engineers.

Key Responsibilities

• Develop and implement advanced composite manufacturing technologies, including Automated Fibre Placement (AFP), Resin Transfer Moulding (RTM), Automated Tape Laying (ATL), autoclave processing and press forming.
• Lead R&D projects focused on new composite materials, manufacturing methods, cost reduction and production efficiency.
• Develop scalable manufacturing processes for aerospace composite structures, including wings and fuselage components.
• Transition new manufacturing technologies from prototype development through New Product Introduction (NPI) into full-scale production.
• Collaborate with design, materials and production engineering teams to improve manufacturability and process capability.
• Lead, mentor and develop a team of manufacturing engineers, initially managing approximately three direct reports.
• Apply Lean Manufacturing, Six Sigma, Design of Experiments (DOE) and Statistical Process Control (SPC) to optimise manufacturing performance.
• Support manufacturing facility expansion, equipment selection and commissioning.
• Develop technical documentation, Design for Manufacturing (DFM) guidelines and process control standards.

Requirements

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Aerospace Engineering, Materials Science or a related discipline.
• 8+ years of manufacturing engineering experience, including composite R&D, process development or New Product Introduction.
• Strong technical experience in at least two composite manufacturing processes, such as autoclave, AFP, RTM, resin infusion, press forming or filament winding.
• Proven experience developing and scaling manufacturing processes from R&D into production.
• Experience leading technical teams and managing engineering development projects.
• Knowledge of DFM, DFA, GD&T, Lean Manufacturing, Six Sigma and process validation methodologies.
• Experience with CAD software, such as CATIA or SolidWorks, and manufacturing systems.
• Familiarity with aerospace quality standards and manufacturing requirements.
• Composite manufacturing experience within aerospace, eVTOL or electric aircraft programmes.
• Development of large structural composite components, including wings and fuselages.
• Experience with advanced materials, composite suppliers or Tier 1/Tier 2 aerospace manufacturers.
• Knowledge of AS9100, NADCAP and FAA Part 21 requirements.
• Experience implementing new manufacturing equipment, technologies or production facilities.
• Advanced degree in Materials Science, Manufacturing Engineering or a related discipline.

Apply

If you're an experienced Composites Manufacturing Engineer, R&D Engineering Lead, Materials & Processes Engineer or Advanced Manufacturing Engineering Manager looking to lead innovative aerospace manufacturing projects, we'd like to hear from you.

Contact Kensington360 for a confidential discussion or apply directly to learn more.