Director of Advanced Manufacturing (Metal/Composite Fabrication)

The Director of Advanced Manufacturing is responsible for the strategic development, deployment, and continuous improvement of advanced manufacturing capabilities in metal and composite fabrication. This role leads cross-functional teams to implement cutting-edge technologies, optimize production workflows, and ensure scalable, cost-effective, and high-quality fabrication of components for critical applications such as aerospace, defense, or industrial machinery.

Key Responsibilities:

🛠️ Strategic Leadership

• Define and execute the vision for advanced manufacturing in metal and composite fabrication

• Develop multi-year roadmaps for capital investments, technology upgrades, and capability expansion

• Drive alignment between R&D, engineering, and operations for seamless industrialization of new products

🧪 Process & Technology Development

• Lead development and optimization of fabrication processes: CNC machining, composite layup, autoclave curing, robotic welding, 3D metal printing, laser cutting, etc.

• Establish in-house expertise in composite manufacturing techniques (resin transfer molding, filament winding, prepreg layup, etc.)

• Evaluate and implement Industry 4.0 technologies, digital twins, IoT-based process monitoring, and automation

⚙️ Production Scale-up & Optimization

• Scale prototypes and pre-production units into high-quality, repeatable, and cost-effective manufacturing processes

• Improve throughput and reduce waste via lean manufacturing, Six Sigma, and value stream mapping

• Collaborate with quality and NDT teams to ensure defect-free production and root cause resolution

🔍 Compliance & Quality Assurance

• Ensure strict compliance with industry standards: AS9100, ISO 9001, NADCAP, ASTM, AWS, etc.

• Oversee validation and certification of new fabrication methods and material specifications

• Ensure traceability, documentation, and statistical process control (SPC) for all critical parts

👥 Team Leadership & Development

• Build and mentor high-performing teams of engineers, manufacturing specialists, and technicians

• Foster a culture of innovation, accountability, and continuous improvement

• Lead cross-functional communication with design, sourcing, program management, and suppliers

Key Focus Areas:

• Advanced fabrication techniques for both metal and composite structures

• Automation, robotics, and digital manufacturing

• Material and process qualification for aerospace/defense-grade parts

• Manufacturing readiness and new product introduction (NPI/NPD)

• Talent development and technology transfer

Required Qualifications:

• Bachelor’s or Master’s degree in Mechanical, Aerospace, Manufacturing Engineering, or related field

• 15+ years of experience in manufacturing, with at least 5 years in composite and/or metal fabrication leadership roles

• Proven track record in launching and scaling high-precision manufacturing lines for mission-critical components

Preferred Skills & Experience:

• Deep expertise in composite materials, metallic structures, tooling, and process engineering

• Hands-on experience with autoclaves, RTM, CMM, CNC, FSW, and additive manufacturing

• Strong understanding of material science, tolerancing, and design-for-manufacture principles

• Proficient in ERP/MES systems, CAD/CAM software, and simulation tools

Certifications (Preferred):

• Six Sigma Black Belt

• PMP or equivalent project management certification

• NADCAP / AS9100 training and quality systems leadership

Working Conditions:

• Office and production floor-based role with occasional travel to global suppliers, customers, and partner facilities

• Requires close interaction with executive leadership and R&D departments