Job Summary:
The Lead Methods Engineer Composites will be responsible for developing, standardizing, and optimizing manufacturing methods for composite structures and components used across Skyroot launch vehicles and associated hardware. This role will lead methods engineering for composites from concept to industrialization, ensuring robust, safe, and cost-effective processes that meet aerospace quality and reliability requirements.
Key Responsibilities:
Methods & Process Development
- Develop and own manufacturing methods for composite components and assemblies (e.g., structures, fairings, motor casings, brackets, panels) across programs.
- Define end-to-end process flows: material preparation, layup, curing (autoclave/oven/OoA), infusion, trimming, machining, bonding, assembly, and inspection.
- Create and maintain process specifications, work instructions, routing sheets, job cards, and method sheets for shop-floor execution.
Industrialization & Optimization
- Lead industrialization of new composite designs into production, including trials, first-article builds, and process validation.
- Optimize cycle times, material utilization, takt, and throughput while maintaining flight-quality standards and safety margins.
- Apply lean, Six Sigma, and data-driven problem solving (RCA, PFMEA, control plans) to improve yield, reduce rework, and stabilize processes.
Tooling & Equipment
- Define tooling concepts and requirements (moulds, mandrels, fixtures, layup tools, assembly jigs) to enable repeatable, high-precision composite manufacturing.
- Collaborate with tooling, design, and suppliers on design, commissioning, and qualification of composite tooling and related equipment (autoclaves, ovens, vacuum systems, cutting/machining tools).
- Establish preventive maintenance and calibration requirements relevant to composite methods (temperature, pressure, vacuum, curing profiles).
Quality, Compliance & Documentation
- Work closely with Quality to define in-process and final inspection methods (NDT, dimensional checks, visual criteria, cure/porosity checks) for composite parts.
- Support NCR investigations, root cause analysis, and development of repair/rework plans for composite non-conformances.
- Ensure methods comply with aerospace standards, internal specifications, and customer/program requirements for flight hardware.
Cross-functional Collaboration
- Partner with Design, Stress, Materials, Production, and Supply Chain teams to ensure manufacturability (DFM/DFx) of composite designs.
- Provide technical guidance and mentoring to methods and production engineers on composite processes, best practices, and troubleshooting.
- Represent methods engineering in design reviews, MRB boards, and program reviews for composite hardware.
Continuous Improvement & Technology Roadmap
- Evaluate and introduce new composite materials, processes, and automation technologies (e.g., AFP/ATL, advanced resin systems, OoA processes) aligned with Skyroot's roadmap.
- Benchmark industry best practices in aerospace composites and translate them into improvements in Skyroot's methods and standards.
Qualifications:
- Bachelor's degree in Mechanical, Aerospace, Materials, or Manufacturing Engineering; Master's degree preferred.
- Minimum 10 years of experience in composite manufacturing/methods engineering in aerospace or high-performance composites (space, aviation, defense).
- Mandatory: Deep, hands-on experience with composite processes such as prepreg layup, vacuum bagging, autoclave/oven curing, RTM/infusion, and composite assembly/bonding.
Skills & Competencies:
- Strong understanding of composite materials (carbon fiber, glass, resins), cure chemistry, defects, and failure modes.
- Expertise in process documentation (work instructions, routers, PFMEA, control plans) and production support in a shop-floor environment.
- Familiarity with aerospace quality frameworks and standards (e.g., AS9100, NADCAP for composites) is an advantage.
- Proficiency with CAD/CAM and PLM tools for interpreting models and drawings; ability to work closely with design data.
- Strong analytical, problem-solving, and data interpretation skills; ability to lead cross-functional teams and drive decisions.
- Excellent communication, documentation, and stakeholder management skills in a fast-paced startup environment.
