SUMMARY:
This position combines strong mechanical and aerospace engineering skills with cross-functional collaboration to establish complete, clear design data packages for manufacturing. Reporting directly to the Engineering Development Manager, the Manufacturing Engineer ensures designs, analyses, and documentation meet the exacting standards of vintage and modern aviation while driving on-time delivery, superior quality, safety, and continuous improvement.
RESPONSIBILITIES:
Design for Manufacturing
- Collaborate with fabrication planning and quality personnel to ensure all aspects of customer designs are procurable and manufacturable.
- Assess customer-provided design data at project initiation for Build-to-Print initiatives.
- Develop best practices and process improvements for production-ready design data packages.
- Modern Aerospace Customer Fabrication: Review customer-provided data packages to verify that all material and finish specifications are achievable within AirCorps’ manufacturing quality systems (e.g., ISO 9001). Alert the Engineering Design Manager when geometry, tolerances, or 3D modeling require review or rework. Collaborate with the Process Technician/Estimator to establish appropriate workflows for manufacturing job creation. After contract receipt, verify the design data package remains unchanged.
- Warbird / Vintage Aircraft Customer Fabrication: Review customer requests for components and assemblies to determine if suitable engineering data exists. Provide modern specifications for historic materials and finishes. Incorporate customer modification requests (e.g., full size/pilot/no holes, primer only, no finishes). Work with the Fabrication team to verify manufacturability of all processes. Incorporate necessary changes for a manufacturable design, coordinate with customers, and control modified design data per AirCorps SOP. Work with Fabrication Quality to ensure parts conform to design data at final inspection.
- PMA Prototype / Conformance Article Fabrication: Review initial design data packages. Collaborate with the Certification Engineer, Fabrication Personnel, and Quality Technicians to optimize designs for manufacturability and ease of conformity. Participate in or delegate fabrication of prototype articles. Assist the Certification Engineer with initial conformance inspection and/or testing.
Technical Design & Analysis
- Assist with detailed mechanical designs, giving careful consideration to fits, tolerances, materials, and manufacturability.
- Develop bills of materials using original documentation, engineering judgment, and supplier input to optimize quality and cost.
- Perform structural, material compatibility, and alternate material analyses to ensure suitability for legacy and custom components.
Process & Documentation
- Author and maintain process documentation, SOPs, and technical instructions to guide production teams.
- Support the development and implementation of new processes, products, and continuous improvement initiatives.
- Efficiently navigate AirCorps’ digital and physical libraries of drawings, manuals, and technical resources.
Quality, Safety & Compliance
- Maintain rigorous adherence to safety protocols, proper use of PPE, and awareness of safety-sensitive operations.
- Identify and promptly report potential hazards to people, property, or equipment.
- Complete and maintain accurate project records, documentation, and quality paperwork.
Customer & Vendor Engagement
- Provide exceptional communication and service to customers and vendors in support of assigned projects.
- Evaluate supplier pricing and component options to maximize gross margin and cash flow while preserving quality standards.
Professional Growth & Productivity
- Work efficiently with minimal supervision while consistently meeting project schedules, budgets, and quality expectations.
- Adapt flexibly to evolving project requirements and priorities.
- Proactively seek opportunities to build new skills and contribute to team success.
QUALIFICATIONS:
- Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a closely related engineering field (required; ABET-accredited program preferred).
- 2+ years of hands-on experience in a manufacturing, aerospace, or related technical environment (preferred; entry-level candidates with strong academic projects, internships, or co-op experience will be considered).
- Strong technical foundation in mechanical design, materials selection, structural analysis, and manufacturing processes.
- Familiarity with structural component manufacturing processes, including CNC machining, sheet metal forming, anodic coatings, welding, heat treatment, and non-destructive inspections.
- Excellent organizational, time management, and attention-to-detail skills with a proven ability to meet deadlines.
- Ability to read, write, and speak English clearly and professionally.
- Willingness and ability to travel occasionally to support customer projects or supplier visits.
- Physical capability to lift and move objects up to 50 pounds and work in a mixed office/shop environment.
- Familiarity with metallurgy, ASME Y14 drafting standards, ISO quality systems, FAA certification processes, or vintage aircraft restoration is a strong plus.
- Passion for aviation, historic aircraft, precision manufacturing, or high-quality craftsmanship is highly desirable.
