Position Overview
TS Conductor is seeking a Senior Composites Manufacturing Engineer to lead process improvement in our composite core pultrusion operations. This hands-on role will work closely with Production, Quality, Maintenance, and R&D to improve product consistency, increase throughput, reduce scrap, and scale manufacturing processes for advanced overhead conductors.
Key Responsibilities
- Own and optimize pultrusion process parameters, including fiber tension and alignment, resin impregnation, die temperature profiles, cure conditions, and pulling speed.
- Troubleshoot production defects and process instability; identify root causes and implement corrective actions that prevent recurrence.
- Plan and execute trials to evaluate fibers, resin systems, sizing compatibility, tooling, and process changes; translate results into stable production practices.
- Use production data, statistical process control, and designed experiments to improve yield, throughput, process capability, and material utilization.
- Develop and maintain process specifications, operating procedures, control plans, and troubleshooting guides; train and coach production teams.
- Partner with Quality and R&D to connect process conditions with composite mechanical and thermal performance and support material and process qualification.
- Support equipment upgrades, new line commissioning, and production scale-up while maintaining safe material handling and operating practices.
Required Qualifications
- At least 5 years of experience in composite manufacturing, with hands-on responsibility for process engineering, troubleshooting, or production improvement.
- Strong understanding of fiber-reinforced polymer composites, resin processing, cure behavior, and the relationship between processing and material properties.
- Demonstrated ability to solve manufacturing problems using data, structured root cause analysis, and practical shop-floor experimentation.
- Ability to lead improvement projects and communicate effectively with operators, engineers, suppliers, and cross-functional teams.
Preferred Qualifications
- Master's or advanced degree in Materials Science, Materials Engineering, Polymer Science, or a related engineering discipline.
- Direct pultrusion experience, particularly with continuous carbon fiber and thermoset resin systems, is preferred.
- Experience with composite characterization, mechanical testing, thermal analysis, and Lean or Six Sigma methods.
Work Environment
The Senior Composites Manufacturing Engineer works across office, lab, and safety-sensitive manufacturing settings. They spend much of their time on the shop floor, near large-scale production equipment, observing processes and working with production teams. They also support R&D and Quality Control Testing, designing new manufacturing processes, tests, and experiments to improve product design and production methods and to ensure quality and standards compliance. In the quality lab, they test, document, and analyze data to improve production lines, write instructions, and collaborate with others. Occasional on-site visits to suppliers, vendors, or customers are required to review quality issues or assess material and tooling performance. Occupational health and safety practices are essential in manufacturing environments.