Senior Ceramic Shell Process Manufacturing Engineer

Prattwhitney; Asheville (NC); On-site; USD 108,000 - 205,000; Full time

Job summary

Pratt & Whitney’s Foundry Manufacturing Engineering team in Asheville, NC is seeking a Sr. Ceramic Process Manufacturing Engineer to lead development of shell systems for nickel-based superalloys.

You will drive process improvements, plan shell line startup, and ensure readiness for production while mentoring colleagues. The role requires extensive experience in aerospace investment casting, strong project management, and expertise in ceramic shell processes.

Qualifications

• Bachelor’s degree in Ceramic Engineering, Materials Science, or Metallurgy focused on investment casting shell systems for nickel‑based superalloys.
• Minimum of 8 years of hands‑on experience in aerospace investment casting of nickel superalloys.
• Advanced degree with 5+ years’ experience.
• Six Sigma green belt or equivalent.

Responsibilities

• Lead development of shell systems supporting single‑crystal nickel alloys.
• Plan and execute new shell line startup for single crystal casting at Asheville.
• Develop and deploy standardized engineering practices and change controls.
• Mentor others through standard work and risk mitigation.

Skills

Shell systems

Ceramic processes

Nickel superalloys

Project management

Communication skills

Education

Ceramic engineering or metallurgy degree

Advanced degree

Tools

Laboratory testing procedures

Shell line production equipment

Job description

Date Posted: 2026-09-17 Country: United States of America

Location: US-NC-ASHEVILLE-330 ~ 330 Pratt Whitney Blvd ~ PRATT WHITNEY

Position Role Type: Onsite U.S. Citizen, U.S. Person, or Immigration Status Requirements: U.S. citizenship is required, as only U.S. citizens are authorized to access information under this program/contract.

Security Clearance Type: None/Not Required Security Clearance Status: Not Required

At RTX, the world's largest aerospace and defense company, 185,000 great minds are united by purpose and inspired to make a difference solving the world’s most complex problems. With our three market leading businesses, world-class operations and investments in research and development, we offer capabilities and opportunity no one else can. Together, we push the boundaries of known science and find new ways to connect and protect our world.

Pratt & Whitney is a world leader in the design, manufacture and service of aircraft engines and auxiliary power systems and has been revolutionizing modern flight for over 100 years. Join us and help shape the future of aerospace and defense. Pratt & Whitney is investing at least $400 million through 2030 in a world-class turbine airfoil production facility in Asheville, North Carolina. The new, 1,000,000-square-foot facility will house an advanced casting foundry for the production of turbine airfoils as well as conducting machining, coating and finishing of airfoils onsite. This state-of-the-art facility will also implement best-in-class manufacturing technologies and processes exemplifying industry 4.0 manufacturing principles and will complement existing turbine airfoil work that is done across Pratt & Whitney’s facilities.

Foundry Manufacturing Engineering Team – Sr. Ceramic Process Manufacturing Engineer

The Foundry Manufacturing Engineering team within the Asheville site is seeking an experienced and motivated Sr. Ceramic Process Manufacturing Engineer to support development and qualification of new processes to meet or exceed delivery and quality targets, while assisting in manufacturing readiness for these processes at the Asheville, NC site. The candidate must demonstrate technical project management, interpersonal and team skills, as well as strong communication skills and the ability to multi-task and adapt to changing business requirements.

*This position will be based on-site in Asheville.

What You Will Do:

Lead development of shell systems supporting single‑crystal nickel alloys. Ensure shell integrity through mold preheat, prime slurry rheology control, backup coat permeability, and autoclave dewax parameters specifically tuned for SX casting. Collaborate with solidification engineers to ensure shell compatibility with crystallographic requirements and withdrawal profiles. Plan and execute new shell line start up for single crystal airfoil casting process. Lead development of shell line production processes, work instructions, quality and regulatory requirements, transitioning a proprietary shell line from the Hartford, CT development laboratory and installing, starting up, debugging, and launching a fully functional production shell line inside the Asheville facility. Develop and deploy standardized engineering practices, processes, tools, and methods. Implement and execute engineering changes to meet customer and financial requirements. Ensure MRL (Manufacturing Readiness Level) of new processes aligns to program requirements as hardware transitions from development to production during launch and subsequent volume ramp by identifying and mitigating development program manufacturing risks. Pursue operational excellence as subject matter expert for foundry ceramic processes; Drive product cost reduction and ensure targets are achieved through data driven process improvements and deployment of new technologies. Develop and Mentor others through standard work, best practices, and risk mitigation.

Qualifications – You Must Have:

• Bachelor’s degree in Ceramic Engineering, Materials Science, or Metallurgy specifically focused on investment casting shell systems for nickel‑based superalloys. (Experience in structural ceramics, glass, refractories, tile, cement, or non‑casting-related ceramics will not be considered.)
• Minimum of 8 years of hands‑on experience in aerospace investment casting of single-crystal or directionally solidified nickel superalloys.
• An Advanced Degree in a related field and minimum 5+ years' experience
• Strong Project Engineering/Planning and Communication/Presentation skills are a must for this position.
• US Person Status required due to government contracts.
• Demonstrated expertise in building, qualifying, and controlling multi‑layer ceramic shell systems using fused alumina and silica‑free binders for reactive superalloys.
• Strong knowledge in alumina ceramics, silica‑free binders, and shell‑build processes supporting casting reactive metal superalloys.
• Experience transferring shell‑build processes from development labs into full-rate production environments.
• Experience with laboratory testing procedures and ceramic raw material qualification.
• Six Sigma green belt or equivalent.
• US Citizen status required.
• Demonstrated knowledge of managing technology development tasks, formulating and leading teams to achieve results, and estimating and controlling budgets.

Qualifications – We Value:

• Prior experience launching or running shell rooms at industry leading competitive aerospace investment casting foundries.
• Six Sigma black belt or equivalent.
• Master’s’ degree in Engineering or related technical field.
• 15 or more years of experience in ceramic shell process.
• Familiarity with robotic programming and process automation.
• Broad knowledge of the aerospace industry and experience in turbine engine parts manufacturing.

Role Type Information:

This position is classified as: Onsite: Employees who are working in Onsite roles will work primarily onsite. This includes all production and maintenance employees, as they are essential to the development of our products. Candidates will learn more about role type and current site status throughout the recruiting process. For onsite and hybrid roles, commuting to and from the assigned site is the employee’s personal responsibility. As part of our commitment to maintaining a secure hiring process, candidates may be asked to attend select steps of the interview process in-person at one of our office locations, regardless of whether the role is designated as on-site, hybrid or remote.

Salary range for this role is 107,500 USD - 204,500 USD. The salary range provided is a good faith estimate representative of all experience levels. RTX considers several factors when extending an offer, including but not limited to, the role, function and associated responsibilities, a candidate’s work experience, location, education/training, and key skills. Hired applicants may be eligible for benefits, including but not limited to, medical, dental, vision, life insurance, short-term disability, long-term disability, 401(k) match, flexible spending accounts, flexible work schedules, employee assistance program, Employee Scholar Program, parental leave, paid time off, and holidays. Specific benefits are dependent upon the specific business unit as well as whether or not the position is covered by a collective‑bargaining agreement. Hired applicants may be eligible for annual short-term and/or long-term incentive compensation programs depending on the level of the position and whether or not it is covered by a collective-bargaining agreement. Payments under these annual programs are not guaranteed and are dependent upon a variety of factors including, but not limited to, individual performance, business unit performance, and/or the company’s performance.

This role is a U.S.-based role. If the successful candidate resides in a U.S. territory, the appropriate pay structure and benefits will apply. RTX anticipates the application window closing approximately 40 days from the date the notice was posted. However, factors such as candidate flow and business necessity may require RTX to shorten or extend the application window.

RTX is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability or veteran status, or any other applicable state or federal protected class. RTX provides affirmative action in employment for qualified Individuals with a Disability and Protected Veterans in compliance with Section 503 of the Rehabilitation Act and the Vietnam Era Veterans’ Readjustment Assistance Act.

Privacy Policy and Terms

RTX is an aerospace and defense company that provides advanced systems and services for commercial, military and government customers worldwide. It comprises three industry-leading businesses – Collins Aerospace, Pratt & Whitney, and Raytheon. Its 195,000 employees enable the company to operate at the edge of known science as they imagine and deliver solutions that push the boundaries in quantum physics, electric propulsion, directed energy, hypersonics, avionics and cybersecurity. The company, formed in 2020 through the combination of Raytheon Company and the United Technologies Corporation aerospace businesses, is headquartered in Arlington, Virginia.