Senior Manufacturing Engineer IV - Ballistic Composites

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

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.