Senior Build Engineer, Airframe Composites Manufacturing

ABOUT US:

Astro Mechanica is a vertically integrated aerospace company developing a scalable technology platform to power critical infrastructure, mission operations, and the future of flight. We apply aerospace engineering and quality standards across our products, delivering high performance, reliability, and efficiency for the most demanding operating environments. Astro Mechanica is backed by leading venture and strategic investors, including Andreessen Horowitz (a16z), Giant Step Capital, United Airlines Ventures, and Voyager Ventures.

WHO WE ARE:

We’re a team of passionate engineers dedicated to advancing aerospace. We’re generalists with specialist depth, united by a flat structure and a shared obsession with building things that work well. We move fast, stay pragmatic, and let engineering excellence speak louder than hierarchy.

WHO YOU ARE:

You're an engineer with a solid understanding of composite materials and manufacturing techniques, able to rapidly develop a manufacturing process from the ground up to turn engineering data into real hardware. You thrive in a hands-on, interdisciplinary environment where seamless collaboration with design, production, quality, supply chain and all other supporting teams is critical to achieving success. You're excited about building an aircraft manufacturing line from scratch and partnering closely with our manufacturing leaders to build a next-generation aircraft factory.

WHAT YOU’LL DO:

Help stand up Astro Mechanica's airframe manufacturing operation from scratch, including facilities, workflows, tooling concepts, equipment and consumables needs, with a focus on both rapid implementation and future scalability

Work directly with the airframe engineering and design teams to translate designs, analyses, and requirements into executable manufacturing plans

Support and coordinate layup, bonding, curing, trimming, assembly, and rework activities to meet aggressive development milestones

Establish and continuously improve manufacturing processes, build sequences, tooling approaches, and process documentation

Maintain strong presence on production floor to drive builds and resolve issues

Collaborate cross-functionally with Design, Tooling, Quality, and Production teams to ensure manufacturability and smooth execution

Create manufacturing instructions and support development of internal processes specifications

Design tools and fixtures directly or via collaboration with internal tool design team or contractors (Also support management of tool schedule and delivery to factory and setup)

Be responsible for quality inspection of the products you will produce

Collaborate with suppliers to develop processes, procure composite parts and materials

Perform first article inspections to ensure initial builds meet dimensional and quality standards

Seek out new manufacturing techniques and technologies that will increase manufacturing throughput and quality

WHAT WE’RE LOOKING FOR:

7+ years of experience in high variability composite manufacturing, including prototyping and airframe fabrication

Experience working with composite materials and processes (prepreg layup, wet layup, bonding, curing, trimming, repair, drilling and fastening)

Experience developing manufacturing processes for complex composite layups and/or aerostructure assemblies from the ground up

Experience working with metallic airframe components and composite-to-metal interfaces

Experience building or scaling manufacturing operations, labs, or shops in a development or flight hardware environment

Experience mentoring and partnering with technicians

Experience working directly from engineering drawings, ply books, CAD models, and evolving build definitions

Strong project management skills

Proficiency in at least one industry standard CAD system, preferably NX

Demonstrated experience designing and developing composite tools and/or assembly fixtures

Strong understanding of GD&T

Experience providing DFM feedback

Experience with quality inspection methods (dimensional, NDI, in-process)

Familiarity with destructive and non-destructive test methods common to composites manufacturing

NICE TO HAVE:

Experience with PLM and/or MES systems

Experience working with laser projection systems to aid composite manufacturing and assembly processes

Experience with CNC ply cutting tools and ply pattern generation in CAD

Experience with AFP/ATL manufacturing systems

Experience with CAM systems from both a programming and operating perspective

Experience with mechanical design, assembly of mechanical systems

Experience with aircraft or spacecraft integration

Experience with metrology tools (CMM, Laser tracker)

Experience manufacturing large structures

Experience in high-volume manufacturing environment

PERKS & BENEFITS:

Comprehensive medical, dental, and vision insurance, including Flexible Spending Accounts (FSA)

401(k) program and transparent stock option plan

Self-managed and flexible time-off policy, including PTO, paid holidays, and sick time

Flexible work environment

ADDITIONAL INFORMATION:

At Astro Mechanica, we highly value in-office work to foster collaboration and strengthen our company culture. We consider working in the office five days a week an essential part of the employee's role.

Astro Mechanica is an equal opportunity employer. We proudly recruit and hire a diverse workforce and are committed to creating an inclusive environment for all employees.