Aerospace Process Engineer - Molding and Spray Coatings

Job Summary

We're looking for a Process Engineer – Molding & Spray Coatings to support the repair and overhaul of critical gas turbine engine components used in commercial aerospace applications. In this role, you will develop, optimize, and sustain manufacturing processes related to resin molding, protective coatings, chemical cleaning, acid etching, and blending operations. Your work will directly improve product quality, process capability, operational efficiency, and on-time delivery of aerospace components.

Work That Matters

At Chromalloy, your work directly supports aviation safety and reliability. Our teams repair and manufacture critical aerospace components used across the global aviation industry. Whether you're improving processes, supporting operations, solving technical challenges, or driving business performance, your contributions help keep aircraft flying safely around the world.

Location: Windsor, CT

Travel: Occasional travel required

Schedule: On-site

What You’ll Be Doing

• Design and optimize low-pressure hand-injected resin molds, including venting, flow paths, parting lines, and release features to improve part quality and process repeatability.
• Develop and refine resin molding processes, including material selection, mix ratios, cure schedules, and manual injection techniques.
• Troubleshoot manufacturing defects such as voids, incomplete fill, shrinkage, and dimensional nonconformances, implementing corrective actions to improve quality and yield.
• Provide day-to-day engineering support for production operations, including root cause analysis, corrective actions, and continuous improvement initiatives.
• Lead the design, development, procurement, and implementation of process tooling, fixtures, gauging, and equipment required to support production cells.
• Establish and maintain process documentation, including work instructions, operating procedures, specifications, calibration instructions, and quality records.
• Support operator training and work closely with maintenance teams to implement effective preventive maintenance programs.
• Develop and optimize HVLP spray coating processes for aerospace-grade protective coatings.
• Improve chemical cleaning, acid etching, and surface preparation processes to enhance product quality and consistency.
• Develop standardized blending techniques, procedures, and best practices across manufacturing operations.
• Monitor process performance and drive initiatives that improve safety, quality, delivery, and cost.

What We’re Looking For

• Bachelor's degree in Engineering or a related science-based discipline such as Materials Science, Chemistry, or Physics.
• 3+ years of engineering experience in a manufacturing environment; aerospace, MRO, or gas turbine component repair experience preferred.
• Experience with low-pressure or hand-injected resin molding processes and mold design optimization.
• Working knowledge of process development, troubleshooting, root cause analysis, and corrective action methodologies.
• Experience supporting production operations and driving continuous improvement initiatives.
• Ability to interpret technical drawings, specifications, and engineering documents.
• Strong written and verbal communication skills with the ability to collaborate across operations, quality, engineering, and maintenance teams.

Nice to Have

• Experience within aerospace manufacturing, repair, or overhaul environments.
• Proficiency with 3D CAD modeling software such as Siemens NX.
• Experience designing tooling and fixturing for manufacturing applications.
• Knowledge of aerospace protective coating systems, including:
  • Polyurethane coatings
  • Epoxy coatings
  • Aluminized coatings
• Experience with HVLP spray equipment and process optimization.
• Experience with chemical cleaning and acid etching of aerospace alloys.
• Knowledge of aerospace blending techniques and tooling selection.
• Familiarity with Lean Manufacturing, Six Sigma, or continuous improvement methodologies.

Work Environment & Physical Requirements

• Work is performed in both office and manufacturing environments with exposure to production equipment, machinery, and industrial processes.
• Regular interaction with production areas, laboratories, and repair operations is required.
• Ability to stand, walk, bend, reach, and move throughout manufacturing facilities for extended periods.
• Ability to occasionally lift and carry up to 25 pounds.
• Must be able to wear required personal protective equipment (PPE) and comply with all safety policies and procedures.