Composite Materials Science & Process Engineer

Job Summary:  

The Composites Materials Science & Process Engineer is responsible for supporting the development, qualification, optimization, and production of composite materials and manufacturing processes. This hybrid role bridges material science and manufacturing engineering, ensuring composite products meet performance, quality, cost, and manufacturability requirements.

The Composites Materials Science & Process Engineer has experience working with composite materials and manufacturing processes and will serve as a technical resource supporting product development, production operations, material characterization, failure analysis, and continuous improvement initiatives.

This position works closely with Product Engineering, Manufacturing, Quality, Supply Chain, and Operations to improve product performance while driving manufacturing efficiency and process reliability.

       Essential Duties & Responsibilities:

 Materials Engineering

• Evaluate and support the selection of composite materials, including carbon fiber, fiberglass, aramid fibers, core materials, adhesives, and resin systems.
• Develop, maintain, and update material specifications, standards, and qualification requirements.
• Perform material testing and characterization to verify mechanical, thermal, and environmental performance.
• Review supplier-provided material data and support material qualification and approval processes.
• Works with diverse materials including metals, plastics, composites, and semi-conductors to meet design, mechanical, and performance criteria.
• Assess material alternatives by comparing performance, manufacturability, availability, and cost to recommend the most suitable solution for each application.
• Support the evaluation, qualification, and implementation of new materials and advanced composite technologies to improve product performance and manufacturability.
• Collaborates with cross-functional teams in engineering, quality, and operations to ensure successful integration of material solutions.

Process Engineering

• Develop, document, and improve composite manufacturing processes.
• Establish process specifications, manufacturing instructions, and quality requirements.
• Support manufacturing methods including:
  • Hand layup
  • Vacuum bagging
  • Resin infusion (VARTM)
  • Resin Transfer Molding (RTM)
  • Compression molding
  • Injection molding
  • Prepreg layup
  • Autoclave curing
  • Oven curing
  • Composite assembly and bonding
• Define critical process parameters and process control methods.
• Support process validation and qualification activities.

Manufacturing Support

• Provide day-to-day technical support to production operations.
• Investigate manufacturing issues involving defects, yield loss, porosity, delamination, dimensional variation, or cure-related concerns.
• Lead root cause investigations and corrective action implementation.
• Collaborate with operators and supervisors to improve process consistency and productivity.
• Support manufacturing readiness activities for new product introduction (NPI).

Testing & Failure Analysis

• Coordinate and perform material and process validation testing.
• Analyze failures related to composite structures, bonding, environmental exposure, and manufacturing defects.
• Prepare technical reports summarizing findings and recommendations.
• Support qualification testing for customer and regulatory requirements.

Continuous Improvement

• Identify opportunities to reduce scrap, rework, cycle time, and manufacturing costs.
• Apply Lean Manufacturing and Six Sigma methodologies to process improvement projects.
• Ongoing enhancements selecting and qualifying materials (metals, polymers, ceramics, and composites) for performance-critical and cost-sensitive applications.
• Assists in continuous improvement efforts in materials and manufacturing through root cause analysis and corrective/preventive actions.
• Analyze manufacturing and quality data to improve process capability and repeatability.
• Support automation and advanced manufacturing initiatives.
• Support customer technical reviews and audits when required.

       Qualifications & Experience:

Education:

• Bachelor's degree in Materials Science, Mechanical Engineering, Aerospace Engineering, Chemical Engineering, Manufacturing Engineering, or a related discipline.

Experience:

• 2+ years of experience in composites engineering, manufacturing engineering, materials engineering, materials science, or a related role.
• Experience with composite manufacturing processes and materials.
• Knowledge of polymer matrix composites and composite fabrication methods.
• Experience interpreting engineering drawings and technical specifications.
• Familiarity with manufacturing documentation, process controls, and quality systems.

Preferred Qualifications:

• Experience in aerospace, defense, energy, industrial equipment, marine, automotive, or sporting goods industries.
• Familiarity with composite material testing standards (ASTM, ISO, SAE, or equivalent)
• Understanding of composite inspection methods including ultrasonic and non-destructive testing (NDT)
• Experience performing failure analysis and root cause investigations.
• Understanding of laboratory instrumentation and testing techniques.
• Exposure to Lean Manufacturing, Six Sigma, or continuous improvement methodologies.
• Strong analytical and troubleshooting skills.
• Excellent written and verbal communication skills.
• Effective communicator capable of influencing cross-functional teams and presenting findings to technical and non-technical audiences.

Key Competencies

• Hands-on engineering approach
• Technical curiosity and continuous learning
• Structured problem solving
• Strong attention to detail
• Cross-functional collaboration
• Project management
• Initiative and accountability
• Customer-focused mindset

Technical Skills:

Materials Knowledge

• Carbon fiber composites.
• Fiberglass composites.
• Thermoset resin systems
• Epoxy systems
• Vinyl ester resins
• Core materials and adhesives
• Composite bonding technologies

Process Knowledge

• Vacuum infusion
• Autoclave processing
• Prepreg manufacturing
• Cure cycle development
• Process validation
• Tooling and fixture development
• Manufacturing process controls

Analytical Tools

• Root Cause Analysis (5 Why, Fishbone, 8D)
• Statistical Process Control (SPC)
• PFMEA
• Design of Experiments (DOE)
• Data analysis and reporting

       Physical Requirements & Work Environment:

• Lab and office-based role with visits to manufacturing sites as needed.
• Stand or walk for extended periods.
• Occasionally lift items weighing up to 20 pounds.
• Adherence to all safety policies, procedures, and regulatory requirements is mandatory.

QHSE Responsibilities:

At GP&C, we are committed to maintaining the highest standards of Quality, Health, Safety, and Environmental responsibility in all aspects of our operations. We believe that the well-being of our employees, the quality of our products/services, and our environmental stewardship are integral to our success. We expect all employees to adhere to our QHSE protocols and actively participate in contributing to our growing QHSE culture as well as taking pride in their work and continuously seek ways to improve processes and deliverables.