Materials & Process Engineer - Aerospace

Role details

Materials & Process Engineer (Aerospace) - Full time

Location:Phoenix, AZ Position Overview We are seeking an experienced Materials & Process Engineer to support aircraft development, production, and sustainment programs. This role is responsible for evaluating aerospace materials, improving manufacturing processes, supporting certification activities, and ensuring compliance with industry and regulatory standards. The ideal candidate will have strong expertise in aerospace materials, manufacturing methods, testing, and failure analysis, along with the ability to collaborate across engineering, quality, and production teams.

Key Responsibilities

Materials Engineering & Analysis • Evaluate existing aircraft materials for obsolescence, cost reduction opportunities, and performance improvements. • Assess alternative materials and manufacturing processes to improve strength, durability, fatigue life, weight, and overall performance. • Perform material selection, qualification, and validation activities for aerospace applications. • Conduct risk assessments and develop mitigation strategies related to material and process changes.

Manufacturing Process Development • Develop, maintain, and improve manufacturing processes including: + Machining + Forming + Welding + Heat treatment + Chemical milling + Composite fabrication • Create and maintain process specifications, work instructions, and quality control procedures. • Support continuous improvement initiatives to enhance production efficiency and product quality.

Testing & Failure Investigation • Investigate material failures, manufacturing defects, and quality concerns using root cause analysis techniques. • Implement corrective and preventive actions to improve product reliability and process stability. • Support testing activities involving mechanical, environmental, and corrosion evaluations.

Design & Engineering Support • Partner with design engineering teams to ensure designs are manufacturable, cost-effective, and compliant with aerospace requirements. • Provide material and process expertise during design reviews and product development activities. • Recommend design and process improvements that optimize weight, performance, and manufacturing efficiency.

Certification & Compliance • Support regulatory certification efforts by maintaining material specifications, testing documentation, and process control records. • Work with certification authorities and engineering representatives to ensure compliance with aerospace regulations. • Stay current with industry standards, regulatory requirements, and emerging material technologies.

Data Management & Continuous Improvement • Maintain materials databases and support engineering analysis activities. • Utilize statistical methods and engineering analysis tools to support material characterization and process validation. • Drive Lean Manufacturing, cost reduction, and process optimization initiatives.

Required Qualifications

Education • Bachelor's or Master's degree in: + Materials Science & Engineering + Mechanical Engineering + Aerospace Engineering + Or a related technical discipline

Experience • Minimum 7 years of experience in the aerospace industry. • Strong knowledge of aerospace materials, including: + Metallic alloys + Composite materials + Polymers + Coatings and surface treatments • Experience with material testing and qualification methodologies. • Knowledge of corrosion mechanisms and prevention methods, including: + Stress corrosion + Galvanic corrosion + Intergranular corrosion • Experience performing environmental testing such as: + UV exposure + Thermal cycling + Humidity resistance + Chemical compatibility testing • Experience supporting or leading material allowable and qualification programs.

• Experience working with FAA certification requirements and regulatory authorities.

Preferred Qualifications

• Experience supporting aircraft structures, systems, and cabin interior development programs.
• Knowledge of additive manufacturing technologies.
• Familiarity with: + CATIA V5 + Siemens NX + Teamcenter PLM
• Experience using Agile project management tools such as Jira and Confluence.
• Knowledge of honeycomb sandwich panel construction and repair methods.
• Understanding of bonded joints, inserts, panel pins, and aerospace joining techniques.
• Strong understanding of aerospace fastening systems and assembly methods.
• Experience operating or supporting testing equipment such as: + Load frames + Environmental chambers + Burn test cabinets + Mechanical test systems

Desired Skills • Strong analytical and problem-solving abilities. • Excellent technical documentation and communication skills. • Ability to manage multiple projects and priorities simultaneously. • Strong collaboration and teamwork skills. • Ability to effectively communicate technical risks, recommendations, and solutions to stakeholders. • Commitment to quality, safety, and continuous improvement.

What You'll Gain • Opportunity to work on advanced aerospace and aircraft development programs. • Exposure to innovative materials, manufacturing technologies, and certification activities. • Collaborative engineering environment focused on technical excellence and continuous improvement. • Professional growth opportunities within a dynamic aerospace organization. • Competitive compensation and benefits package.