Automated Fiber Placement (AFP) Manufacturing Engineer II

Pay Range: $95,000–$125,000 annually

Job Summary

DIRECT HIRE: The AFP Manufacturing Engineer II develops, programs, and optimizes automated composite layup processes using Ingersoll AFP systems. This role supports aerospace manufacturing by improving part quality, reducing cycle times and material waste, troubleshooting production issues, and ensuring composite components meet engineering and manufacturing requirements.

Key Responsibilities:

• Develop and manage AFP ply programs using Ingersoll Gen2, Vericut Composite Programming (VCP), and Vericut Composite Simulation (VCS)
• Translate engineering models, ply books, and lamination schedules into accurate AFP toolpaths, ensuring correct fiber orientation, material coverage, and placement boundaries
• Support AFP machine setup, calibration, laser alignment, first-article production, and repeatable manufacturing operations
• Validate AFP programs through simulation and dry runs and collaborate with machine operators during production startup
• Analyze and optimize machine paths and operating parameters to reduce gaps, overlaps, tow steering errors, material waste, and production cycle times
• Provide design-for-manufacturability (DFM) feedback to design engineering teams to improve composite part manufacturability
• Troubleshoot AFP equipment and process issues in collaboration with maintenance personnel and Ingersoll technical support
• Participate in tooling design reviews to verify compatibility with AFP equipment, placement heads, access requirements, and laser projection systems
• Identify, implement, and document process improvements, automation enhancements, and material usage reductions
• Develop and maintain standard work instructions, AFP best practices, preventive maintenance plans, and critical spare-parts documentation
• Support quality audits, root-cause investigations, nonconformance reviews, and corrective actions related to AFP-manufactured components
• Collaborate with design engineering, NC programming, operations, quality, maintenance, and facilities teams to maintain production quality and efficiency
• Manage multiple priorities and deadlines while maintaining professional communication, punctuality, and reliable attendance

Required Qualifications

• Bachelor's degree in Mechanical Engineering or a related engineering field
• Minimum of 5 years of experience in carbon fiber composite aerospace manufacturing
• Hands-on experience with Automated Fiber Placement (AFP) manufacturing processes and programming
• Proficiency in CAD software and AFP programming tools
• Experience analyzing machine efficiency and implementing process improvements to reduce cycle time, waste, and production costs
• Strong technical aptitude and the ability to learn complex equipment and manufacturing systems.
• Excellent problem-solving, analytical, and troubleshooting skills
• Demonstrated ability to drive process improvements and deliver measurable results in a fast-paced manufacturing environment
• Strong written and verbal communication skills in English
• Ability to work independently, take initiative, and collaborate effectively with cross-functional teams

Preferred Qualifications

• 5+ years of experience in aerospace manufacturing or engineering
• Experience implementing capital equipment and automated manufacturing systems
• Master's degree in Mechanical Engineering, Aerospace Engineering, or a related discipline
• Six Sigma Black Belt or Lean Manufacturing Black Belt certification

Required Certifications

• No specific certification is explicitly listed as required
• Six Sigma Black Belt or Lean Manufacturing Black Belt certification is preferred