The Senior Materials Engineer provides technical leadership for the selection, development, testing, and qualification of aerospace metals and composite materials used in critical structural and mechanical applications. This role oversees materials engineering strategies, drives problem-solving for complex materials challenges, and ensures compliance with rigorous aerospace standards. The senior engineer mentors teams, manages supplier relations, and collaborates cross-functionally to optimize materials performance and support product certification and lifecycle sustainment.
Key Responsibilities:
Lead materials selection and qualification activities for aerospace metals (aluminum, titanium, steels) and composites (carbon fiber, thermoset/thermoplastic matrices) across multiple programs
Develop and oversee comprehensive test programs, including mechanical, thermal, fatigue, corrosion, fracture toughness, and environmental durability testing
Analyze complex test data and failure modes to provide actionable insights and recommendations for design improvements and corrective actions
Drive root cause investigations and implement effective mitigation strategies for material-related anomalies or in-service failures
Manage supplier qualification and audits to ensure material traceability, quality, and conformance to aerospace standards (AS9100, NADCAP)
Collaborate closely with design, manufacturing, quality, and supply chain teams to integrate material solutions that meet performance, cost, and schedule goals
Lead cross-disciplinary materials reviews and represent the company in customer and certification authority meetings
Mentor junior and mid-level materials engineers and contribute to technical training programs
Continuously improve materials engineering processes, standards, and documentation practices
Stay current with emerging materials technologies, industry trends, and regulatory requirements to inform strategic decisions
Key Focus Areas:
Strategic materials engineering leadership for aerospace metals and composites
Advanced materials testing, qualification, and failure analysis
Supplier management and aerospace quality compliance
Cross-functional collaboration and technical mentorship
Qualifications & Skills:
Education:
Bachelor’s degree in Materials Science and Engineering, Metallurgical Engineering, Aerospace Engineering, or related field (required)
Master’s or PhD preferred
Certifications:
Advanced materials testing and quality certifications (e.g., ASTM, NACE, NADCAP) preferred
Six Sigma Black Belt or equivalent process improvement certification a plus
Experience:
8–15+ years of experience in aerospace or similarly demanding industries with metals and composite materials
Proven track record leading complex materials qualification programs and failure investigations
Experience managing supplier relations and material certification processes
Deep knowledge of aerospace materials properties, processing methods, and failure mechanisms
Technical Skills:
Expert knowledge of mechanical, thermal, and environmental testing methods for metals and composites
Skilled in failure mode and effects analysis (FMEA), root cause analysis, and corrective action implementation
Familiarity with materials modeling and simulation tools is a plus
Proficient in data analytics software and materials database management
Soft Skills:
Strong leadership and project management skills
Excellent communication, negotiation, and stakeholder engagement abilities
Strategic thinker with the ability to influence cross-functional teams
Committed to mentoring and developing technical talent