Were seeking a Senior Automated Fiber Placement (AFP) Manufacturing Engineer to join a cutting-edge composites team working with one of the most advanced AFP machines in the world. This is a high-impact, highly specialized role focused on programming, process optimization, and cross-functional collaborationnot machine operation.
In this role, youll also be expected to have a comprehensive understanding of CNC machining and programming operations, contributing to the development of the largest liquid-filled all-composite rocket ever built. Youll work closely with Manufacturing Technicians, Engineers, and Design teams to optimize machining programs and procedures in a high-mix, low-volume environment.
This is a single-point-of-contact role for AFP operations, requiring a high level of ownership and availability, including on-call support during weekends.
Key Responsibilities
AFP & ATL Engineering:
Program and optimize AFP/ATL machines for complex composite layups
Develop and refine tool paths, steering strategies, and ply placement
Interface with machine controllers and proprietary programming environments
Collaborate with design, tooling, and quality teams to ensure manufacturability
Support preventive maintenance and machine troubleshooting (not operation)
Drive continuous improvement in layup quality, cycle time, and material utilization
Contribute to the development of digital work instructions and standard work
Participate in root cause analysis and corrective actions for AFP-related issues
CNC Programming & Machining:
Generate and maintain CNC programs and setup sheets
Define and adjust speed/feed parameters for tool life and performance
Suggest drawing changes to improve manufacturability and programming strategy
Design and machine fixture tooling as needed
Digitally proof programs and simulate tool paths to avoid machine crashes
Use Siemens NX for surface modeling, tool path generation, and simulation
Understand gantry kinematics and interpret output files
Monitor machine response to programs and optimize accordingly
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510+ years in aerospace composites, with a focus on AFP, ATL, or automated layup
5+ years programming for 5-axis milling or large-format gantry operations
Experience with AFP machines (Ingersoll, Electroimpact, MTorres, Coriolis)
Proficiency in CATIA V5/V6 (CPD/FFD), Siemens Fibersim, and NX
Strong understanding of tool path generation, collision avoidance, and offline programming
Familiarity with composite materials (prepreg, thermoplastic, out-of-autoclave)
Experience with layup tooling, vacuum checks, cure cycles, and bonding operations
Comfortable with NC programming, machine calibration, and machine interface systems
Knowledge of industry specs like AS9100, NASA-STD-5009, or OEM-specific standards
Willingness to be hands-on with machines and optimize through direct observation
Masters degree in Mechanical or Manufacturing Engineering
10+ years of CNC programming experience
Experience with multi-axis mill and lathe CNC machines
Coding skills in Python, macros, Visual Basic, Excel scripting, or file parsing/editing
Experience with MES, ERP, and PLM tools (e.g., Windchill, Teamcenter)
Lean Manufacturing or Six Sigma Green/Black Belt certification
Familiarity with statistical process control (SPC) and capability analysis
Background in scaling AFP from prototype to rate production
Benefit packages for this role will start on the 31st day of employment and include medical, dental, and vision insurance, as well as HSA, FSA, and DCFSA account options, and 401k retirement account access with employer matching. Employees in this role are also entitled to paid sick leave and/or other paid time off as provided by applicable law.