Lead Materials & Process Engineer

Supernal - Irvine, CA

Full-time - Senior

Irvine, CA

Transportation Equipment Manufacturing

About the position

The Lead Materials & Process Engineer at Supernal will leverage their technical expertise to support the development of electric vertical take-off and landing (eVTOL) vehicles. This role focuses on implementing both conventional and innovative materials and processes, ensuring that hardware meets safety and reliability standards for certification and production. The engineer will collaborate with various engineering and supply chain teams, manage workflows, and mentor junior engineers while contributing to the advancement of the Advanced Air Mobility (AAM) industry.

Responsibilities

• Be responsible for the Materials & Process team's workflows focusing on composites and structural bonding.
• Coordinate crafting design requirements & standard methodologies for all hardware on the vehicle.
• Own the evaluation & selection of composite materials & adhesives to satisfy design requirements.
• Coordinate the development of adhesively bonded joints & assemblies.
• Build internal material specifications and process specifications that support manufacturing & ensure quality.
• Lead & coordinate testing for method development, materials characterization, allowables generation, and design validation.
• Serve as the M&P representative (Signatory Authority) in design reviews, production drawing release cycle for hardware components/assemblies, & Material Review Board (MRB) issues.
• Coordinate supplier selection, development, qualifications, and ongoing evaluations.
• Build procedures for reviewing supplier-delivered hardware for compliance with requirements.
• Assist in building top-level M&P control plans and documentation.
• Support the manufacture of hardware in-house and at suppliers.
• Participate in industry working groups, standards bodies, and relevant technical conferences to maintain awareness of technology developments & regulatory trends.
• Mentor junior engineers.
• Partner with PMO organization to implement build plan.

Requirements

• Bachelor's Degree in STEM or related field required; Master's or Ph.D. degree preferred.
• Minimum ten (10) years of related experience.
• Experience in thermoset fiber composites, thermoplastic fiber composites, structural bonding, adhesives, and plastics.
• Experience with physical & mechanical material characterization, composite material allowables generation & certification.
• Experience with qualification and implementation of automated/robotic composite processes.
• Knowledge of process mapping, SPC, PFMEA, DFMEA, and similar tools/techniques.
• Familiarity with 3D CAD software (CATIA, SolidWorks, NX, or similar).
• Proficiency in drafting test plans, coordinating & implementing test campaigns, and generating test reports.
• Ability to run materials characterization lab equipment such as FTIR, DSC, SEM, TGA, Rheometer, and Instrons.
• Ability to perform composite layups and bagging and run equipment related to composite fabrication.
• Ability to lift/move equipment and tools weighing up to 35lbs.
• Familiarity with statistical software, including Minitab, JMP, or similar.
• Knowledge of CMH-17, SAE, ASTM, and other standard bodies.
• Understanding of Six Sigma, Lean, & DOE principles.
• Proficiency in writing R&D work instructions and documentation of R&D work.
• Understanding of composites & adhesive materials and processing methods used for various applications in aircraft structures.
• Ability to lead material allowable certification programs and fabrication methods in a high-rate manufacturing environment.
• Proficiency in MS Office Suite tools such as Word, Excel, Project & Visio.
• Excellent organizational skills and attention to detail.
• Ability to independently prioritize and accomplish work in a timely manner.

Nice-to-haves

• Six Sigma Green Belt or higher preferred.
• Experience with aerospace assembly processes preferred.

Benefits

• Base pay offered may vary depending on skills, experience, job-related knowledge and location.
• Eligible for a bonus as part of total compensation.