The Director of Aerospace Fabrication and Assembly is responsible for leading the strategic and operational execution of fabrication and assembly processes for aerospace components and systems. This role ensures delivery of high-quality, cost-effective products that meet rigorous aerospace standards. The Director leads cross-functional teams across metal/composite fabrication, structural assembly, systems integration, and testing—driving continuous improvement, efficiency, and compliance.
Oversee all aspects of fabrication (metal and composite) and final assembly for aerospace structures such as airframes, fuselage sections, nacelles, control surfaces, and satellite enclosures
Ensure production goals (quality, cost, delivery, safety) are met across manufacturing work cells and assembly lines
Direct the implementation of complex jigs, fixtures, and tooling for precision alignment and assembly
Develop and refine processes for welding, forming, machining, bonding, fastening, and systems integration
Support qualification of new processes and materials under AS9100, NADCAP, and FAA/EASA regulations
Ensure manufacturing readiness for new product introduction (NPI) and engineering change implementation
Lead planning and execution of production capacity expansion and facility upgrades
Utilize lean manufacturing, Six Sigma, and Industry 4.0 principles to reduce lead time and increase throughput
Monitor and report key performance indicators (KPIs) related to efficiency, rework, scrap, and delivery performance
Ensure compliance with aerospace industry standards (AS9100, ISO 9001, NADCAP) and customer specifications
Drive zero-defect culture through root cause analysis, CAPAs, and robust inspection/testing programs
Collaborate closely with Quality Assurance and Regulatory Compliance teams
Manage and mentor managers, engineers, and supervisors across fabrication and assembly teams
Promote cross-functional coordination between manufacturing, quality, engineering, and supply chain
Foster a culture of safety, accountability, continuous improvement, and operational excellence
Metal and composite fabrication (including forming, welding, bonding)
Structural and mechanical assembly of aerospace systems
Manufacturing process innovation and automation
Compliance with AS9100, NADCAP, FAA/EASA standards
Workforce development and leadership
Bachelor’s degree in Mechanical, Aerospace, Manufacturing Engineering or related discipline (Master’s preferred)
15+ years of experience in aerospace manufacturing with 8+ years in fabrication/assembly leadership roles
Strong knowledge of fabrication techniques, tooling, and aerospace materials (aluminum, titanium, carbon composites)
Proven experience managing large teams and complex manufacturing programs
Experience in airframe manufacturing, satellite structures, propulsion systems, or UAV assembly
Deep understanding of ERP/MRP systems (SAP, Oracle), MES, and PLM tools
Familiarity with GD&T, APQP, PFMEA, and DFM/A principles
Strong communication, financial acumen, and stakeholder management skills
Six Sigma Black Belt or Lean Manufacturing Certification
PMP or program leadership certification
NADCAP/AS9100 internal auditor or implementation experience
Position is on-site with regular presence on the production floor
Occasional travel to suppliers, customers, and secondary manufacturing sites
Fast-paced environment with responsibility for high-stakes aerospace program delivery