Senior Engineer Special Processes

ABOUT THE ROLE The Special Processes Senior Engineer is a senior technical and team-leading role responsible for developing, qualifying, and industrializing critical aerospace special processes supporting Powertech s propulsion programs, including turbofan, microjet, and piston engines. The role acts as the technical authority for special process technologies, supporting greenfield manufacturing setup, New Product Introduction (NPI), production industrialization, and process capability development. The Senior Engineer works closely with Manufacturing Engineering, Design Engineering, Quality, Supply Chain, suppliers, equipment vendors, and technology partners while providing day-to-day technical leadership to engineers and technicians within the special processes team. RESPONSIBILITIES Special Process Development & Industrialization • Lead the development, qualification, and continuous improvement of aerospace special processes for rotating, structural, and hot-section engine components. • Provide technical leadership in processes including: • • Shot peening • Thermal spray coatings (HVOF, plasma spray, wear-resistant and environmental coatings) • Heat treatment, vacuum heat treatment, solution treatment, aging, and stress relief • Brazing • Surface preparation, grit blasting, masking, and finishing processes • Cleaning • Chemical processing • Define and review manufacturing routings, process specifications, work instructions, control plans, and acceptance criteria. • Establish process capability requirements and statistical monitoring methods to ensure stable and repeatable production performance. • Lead process validation activities including First Article Inspection (FAI), industrial qualification, capability studies, and production readiness reviews. Greenfield Manufacturing Capability Development • Support the establishment of in-house special process capabilities, including facility layout, equipment specification, supplier selection, commissioning, and process qualification. • Define equipment requirements, utility needs, process controls, and environmental requirements for new special process cells. • Support make-versus-buy evaluations and phased capability development strategies aligned with product and production roadmaps. • Coordinate technology transfer activities from external partners and suppliers into Powertech manufacturing operations. NPI & Program Execution • Lead special process engineering activities during New Product Introduction (NPI) from prototype development through production readiness. • Support manufacturing planning, process qualification, and production ramp-up activities for new engine programs and component families. • Act as the special process focal point for assigned engine modules, components, and development programs. • Ensure process readiness aligns with program schedules, quality requirements, and certification objectives. Design-to-Manufacture & Concurrent Engineering • Support concurrent engineering activities with design teams to ensure components are optimized for manufacturability, process capability, durability, and cost. • Provide technical input during design reviews, material selection activities, tolerance allocation, coating requirements. • Identify and mitigate manufacturing and process qualification risks early in the product development lifecycle. • Support development of process specifications and special process requirements for new component designs. Supplier & Partner Technical Support • Provide technical oversight and support to special process suppliers, subcontractors, and manufacturing partners. • Lead supplier process reviews, technical audits, qualification activities, and process improvement initiatives. • Support supplier industrialization and process capability assessments. • Drive resolution of process-related technical issues across the supply chain. Technical Leadership & Team Support • Provide technical leadership, mentoring, and day-to-day guidance to special process engineers and technicians. BASIC QUALIFICATIONS • Bachelor s or Master s degree in Mechanical Engineering, Materials Engineering, Aerospace Engineering, Manufacturing Engineering, or related discipline. • 8+ years of experience in aerospace manufacturing, with significant experience in special process development and industrialization. • Strong hands-on expertise at least two or more of the following aerospace special process technologies: shot peening, thermal spray coatings, heat treatment, brazing, chemical processing. • Proven experience supporting New Product Introduction (NPI), industrialization, process qualification, and production ramp-up activities. • Experience developing process specifications, qualification plans, control plans, and process validation documentation. • Working knowledge of aerospace materials including titanium alloys, nickel-based superalloys, stainless steels, aluminum alloys, and high-temperature materials. • Familiarity with aerospace quality systems, process qualification methodologies, and special process accreditation requirements. • Experience leading technical activities, mentoring engineers, and providing day-to-day technical guidance. • Ability to work effectively with design, quality, operations, supply chain, partners, and equipment vendors in a concurrent engineering environment.