Composite Technician

Job Title: Composite Technician 
Location: North Kingstown, RI 
Level:  Medium
Client Facing: Yes 

About PAC Group:   

 At The PAC Group (PAC), we specialize in engineering consulting, program management, and operational excellence—delivering high-impact solutions in more than 20 countries. We’re proud to partner with the world’s leading companies in automotive, aerospace, industrial, and technology sectors, providing strategic guidance and hands-on execution that drive innovation and efficiency. Whether we’re launching advanced manufacturing systems, deploying digital simulation tools, or scaling global operations, PAC thrives at the intersection of technology, engineering, and problem-solving.   

Joining PAC means joining a dynamic, fast-paced, and global team that values curiosity, collaboration, and continuous improvement.   

Role Purpose: 

The Composite Technician is responsible for the hands-on fabrication, assembly, repair, and testing of advanced composite structures and components used in next-generation electrified products. This role plays a critical part in supporting prototype development, design validation, and production readiness. The ideal candidate combines deep composites manufacturing expertise with a practical, problem-solving mindset and thrives in a fast-paced startup environment where quality, safety, and innovation are paramount. 

Key Responsibilities: 

Fabricate, assemble, and finish composite components and structures using prepreg, wet layup, vacuum bagging, infusion, and other advanced composite manufacturing techniques. 

Perform mold preparation, material cutting, layup, curing, demolding, trimming, bonding, and finishing operations. 

Operate and maintain composite manufacturing equipment, including ovens, autoclaves, vacuum systems, trimming tools, and inspection equipment. 

Maintain cleanroom/shop standards, calibrate shop tools, and ensure safety and material handling protocols (OSHA, resin safety) are strictly followed. 

Read and interpret complex engineering drawings, CAD models, 3D piles, specifications, technical work instructions, and composite layup schedules. 

Support development, prototype, and production builds of new model. 

Collaborate with design engineers to iterate rapidly on prototype tooling, fixtures, and part modifications in a dynamic environment. 

Work closely with design, manufacturing, and testing engineers to identify and resolve build issues and improve manufacturability. 

Perform structural bonding, mechanical assembly, and integration of composite components with metallic and electrical systems. 

Trim, drill, deburr, and assemble cured composite and multi-material subassemblies to tight engineering tolerances using precision hand and power tools. 

Conduct in-process and first-article inspections using precision measurement tools (calipers, micrometers, depth gauges) to verify part geometry and structural integrity.  

Document manufacturing activities to ensure compliance with quality standards and engineering requirements. 

Identify defects and perform composite repairs as required using approved techniques and procedures. 

Maintain strict adherence to quality standards, safety regulations, and material handling procedures. 

Assist in developing manufacturing processes, tooling concepts, and build documentation for future production. 

Participate in continuous improvement initiatives focused on quality, cost, throughput, and reliability. 

Support test activities as needed, including troubleshooting and modifications. 

Required Qualifications: 

• 5+ years of hands-on experience manufacturing composite structures in aerospace, defense, motorsports, marine, or other high-performance industries. 

• Demonstrated experience with composite fabrication methods including: 

• Prepreg and wet-layup 

• Vacuum bagging and thermal/autoclave or oven curing 

• Resin infusion 

• Structural bonding 

• Composite repair techniques 

• Experience working with carbon fiber, fiberglass, honeycomb core, and sandwich-panel constructions. 

• Ability to read and interpret engineering drawings, GD&T, work instructions, and process specifications. 

• Proficiency using precision measurement tools and fabrication equipment. 

• Strong understanding of composite materials, cure processes, and quality requirements. 

• Experience maintaining accurate manufacturing records and quality documentation. 

• Ability to work independently with minimal supervision while maintaining high-quality workmanship. 

• Strong troubleshooting and problem-solving skills. 

• High school diploma or GED required; technical/vocational certification. 

• Ability to stand for extended periods, wear required personal protective equipment (PPE), lift up to 50 lbs (23 kg), and perform hands-on manufacturing activities. 

• Eligibility to work in the applicable country. 

Preferred Qualifications: 

• Experience building flight hardware for commercial, military, eVTOL, UAV, space, or advanced air mobility programs. 

• Previous experience in an aerospace startup or rapid product development environment. 

• Familiarity with FAA, EASA, AS9100, or equivalent aerospace quality standards. 

• Experience operating autoclaves and developing composite cure cycles. 

• Composite certification from a recognized technical institution or aerospace organization. 

• Experience with non-destructive inspection (NDI/NDT) methods. 

• Knowledge of tooling design, mold fabrication, and manufacturing process development. 

• Experience integrating composite structures with electrical, battery, propulsion, or high-voltage systems. 

• Ability to support prototype builds and transitions into low-rate or full-scale production. 

• Lean manufacturing or continuous improvement experience. 

• Basic exposure to CAD/CAM software (such as CATIA V5, SolidWorks, or AutoCAD) for reviewing ply geometries and digital models. 

• Experience building composite molds, plugs, or master patterns from scratch. 

• Aircraft maintenance, airframe, or aerospace manufacturing background.