Senior Aerospace Composite Manufacturing Engineer

Expleo Group; Washington (District of Columbia); On-site; USD 90,000 - 110,000; Full time

Benefits offered by this job

Competitive compensation

Comprehensive benefits

Paid holidays and time off

Career development

Strong team culture

Job summary

Expleo Group USA seeks experienced Aerospace Manufacturing Engineers to support aerospace programs focused on composite manufacturing, aircraft assembly, process development, tooling design, production readiness, and operational excellence.

Responsibilities include developing processes for composites and assemblies, creating work orders and documentation, and ensuring quality and safety, while collaborating with Design Engineering and Quality teams to optimize manufacturability and drive

Qualifications

• Bachelor's Degree in Manufacturing Engineering, Mechanical Engineering, Aerospace Engineering, Industrial Engineering, or related technical discipline.
• 8+ years of manufacturing engineering experience within aerospace, aviation, defense, or advanced manufacturing environments.
• Experience developing manufacturing work orders, work instructions, routers, travelers, and production process documentation.
• Strong background in composite manufacturing processes, materials, and fabrication techniques.
• Experience supporting aerospace assembly operations and production environments.
• Knowledge of AS9100 and aerospace quality management systems.
• Experience supporting prototype development, low-rate production, and production ramp-up efforts.

Responsibilities

• Develop and implement manufacturing processes for composite structures, subassemblies, and final aircraft assembly operations.
• Support prototype, LRIP, and full-rate manufacturing activities.
• Evaluate methods to identify opportunities for process improvement, cost reduction, and productivity gains.
• Ensure processes meet quality, safety, and production requirements.
• Collaborate with Design Engineering to optimize manufacturability and production efficiency.
• Create and maintain manufacturing work orders, routers, and shop floor documentation.
• Develop clear work instructions for composite fabrication and assembly operations.
• Translate drawings, CAD models, and specs into production-ready processes.
• Support engineering change and configuration management activities.
• Provide guidance and documentation to manufacturing personnel.
• Ensure documentation aligns with customer, regulatory, and aerospace requirements.
• Develop methods for composite layup, bonding, trimming, curing, and assembly.
• Support production teams in executing composite fabrication while maintaining quality and schedule.
• Identify and address manufacturing challenges to improve process capability and product quality.
• Work with Quality teams to resolve nonconformances and improve first-pass yield.
• Assist in transitioning products from development to production environments.
• Contribute to continuous improvement of composite manufacturing processes and best practices.
• Define, develop, and optimize aircraft assembly processes for structures, modules, and integrated systems.
• Support assembly sequencing, work package development, and production planning.
• Participate in manufacturing readiness reviews and production build planning.
• Collaborate with production teams to troubleshoot assembly issues and improve flow.
• Drive standardization and implementation of assembly best practices.
• Support ramp-up activities and operational performance improvements.
• Design and develop tooling, fixtures, and composite layup aids.
• Evaluate tooling effectiveness and implement enhancements to improve quality and safety.
• Collaborate with manufacturing, design, and quality teams to ensure tooling supports production objectives.
• Manage tooling modifications and maintenance requirements.
• Support tooling validation and production readiness assessments.

Skills

Aerospace manufacturing

Process development

Lean manufacturing

PFMEA

Quality systems

Cross-functional collaboration

Interpret CAD drawings

Troubleshooting

Education

Bachelor's Degree in Manufacturing/Mechanical/Aerospace/Industrial Engineering

Tools

MES

ERP systems

3D CAD interpretation

Job description

Expleo Group USA seeks experienced Aerospace Manufacturing Engineers to support aerospace programs focused on composite manufacturing, aircraft assembly, process development, tooling design, production readiness, and operational excellence.

Responsibilities include developing processes for composites and assemblies, creating work orders and documentation, and ensuring quality and safety, while collaborating with Design Engineering and Quality teams to optimize manufacturability and drive