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Staff Manufacturing Engineer (CMC Applications)

Impulse Space
Redondo Beach, USA
Full-time
Senior · 5+ years experience
Onsite
USD 175000-215000 yearly / year
Discovered 1 weeks ago
CVIPIPCVDCTSix SigmaFinite Element Analysis
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Responsibilities

  • Own and mature the end-to-end manufacturing process for C/SiC and related ceramic composite hardware in ultra-high-temperature applications, from preform architecture through densification, machining, and coating.
  • Develop and qualify densification and joining processes (CVI, PIP, brazing), including furnace cycle definition, tooling, fixturing, and run-to-run repeatability.
  • Analyze candidate fiber, matrix, and coating systems and build the supply chain strategy: qualify vendors, dual-source critical materials, and de-risk long-lead precursors.
  • Define the inspection, acceptance, and validation approach for manufactured parts, NDI methods (CT, ultrasonic, thermography), coupon tests, allowable development, and first-article inspection.
  • Author and own process specifications, travelers, and work instructions; drive configuration control and change management.
  • Design tooling, mandrels, and shop aids for CMC part fabrication and assembly.
  • Partner with propulsion, structures, and thermal teams on DFM feedback so producibility is built into the design rather than discovered on the shop floor.
  • Lead root-cause investigations on process escapes and drive corrective actions using RCA and structured problem-solving.
  • Scale from prototype to rate production: capital equipment selection, facility layout, cycle time, yield, and cost per part.
  • Work directly with technicians and machinists on the floor to produce flight hardware.
  • Own the technical roadmap for CMC manufacturing capability, sequencing process development, capital investment, and qualification milestones against vehicle program needs.
  • Mentor engineers and technicians, and influence the technical standard for high-temperature materials manufacturing across the organization.

Minimum Qualifications

  • Bachelor's degree in engineering, materials science, chemistry, physics, or a related technical field.
  • 5+ years of experience developing or producing high-temperature materials or advanced composites, ceramic matrix composites, carbon-carbon, refractory metals, ablatives, or comparable systems; or a Master's degree with 3+ years; or a PhD in a relevant field with 1+ years of hands-on experience.
  • Demonstrated experience in aerospace, defense, hypersonics, gas turbine, nuclear, energy, or industrial ceramics.

Preferred Skills and Experience

  • CMC manufacturing for aerospace or defense flight hardware.
  • SiC matrix densification via CVI, with working knowledge of PIP, CVD, melt infiltration, and the trade-offs between them.
  • Vacuum and high-temperature furnace operation, instrumentation, and maintenance.
  • Rocket engine propulsion fundamentals and hot-section hardware manufacturing, nozzles, throats, combustion chambers, and thermal protection systems.
  • Fiber preform architecture: braiding, filament winding, 2D/3D weaving, additive preforming, and the effect of architecture on densification uniformity.
  • NDI methods for ceramic composites and interpretation of defect indications against acceptance criteria.
  • Finite element analysis of anisotropic and high-temperature materials.
  • Lean manufacturing, Six Sigma, and statistical process control in a low-volume, high-mix environment.
  • Working knowledge of AS9100 or comparable aerospace quality systems.
  • Experience taking a new process from lab or prototype scale into qualified-rate production.

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