Lead Composites Engineer, Tooling & Manufacturing

Role details

Title

Lead Composites Engineer, Tooling & Manufacturing

Job type

Full-time employee

Location

4240 N Nevada Ave Ste 100, Colorado Springs, CO 80907

Overview

PteroDynamics is seeking a hands-on Lead Composites Engineer – Tooling & Manufacturing to own composite tooling and manufacturing process development for Transwing® aircraft structures, and to serve as the composites technical lead between our design and manufacturing teams. The larger part of this role is manufacturing facing: designing composite tooling, developing and implementing layup, bagging, and cure processes, and bringing advanced composite parts from prototype to repeatable production.

The role also works closely with our design engineering team of aerospace engineers, helping define laminate schedules and material selections, performing DFM and DFA reviews, and using FEA results to inform laminate and material decisions. This is a full-time, on-site individual contributor role in a fast-moving startup. The successful candidate will be self-directed, equally comfortable in CAD and on the shop floor, and able to balance speed with the rigor that flight hardware demands.

About Us

PteroDynamics Inc. designs superior autonomous vertical takeoff and landing (VTOL) aircraft systems that fly faster and go farther to reach remote locations without runways, even in harsh conditions. PteroDynamics’ Transwing® aircraft is unlike any other VTOL system, performing like a great fixed-wing aircraft with superb VTOL capabilities.

Transwing aircraft unfold their wings to transition smoothly and quickly between vertical and horizontal flight, overcoming limitations inherent in other VTOL designs by combining fixed-wing aircraft speed, range, and endurance with superior VTOL performance in an efficient, highly automated platform. The Transwing is ideal for automating time-sensitive delivery of critical high-value payloads to hard-to-reach locations, including maritime logistics support, payload delivery to remote locations without airstrips, and reconnaissance and surveillance. Seeing is believing. Visit www.PteroDynamics.com for details and videos.

About the Role

This is an opportunity to take ownership of composite tooling and manufacturing processes in a fast-moving aerospace environment. You'll play a key role in developing tooling, refining fabrication methods, and transitioning composite components from prototype to repeatable production.

Working alongside design engineers and manufacturing technicians, you'll help improve manufacturability, optimize production processes, and introduce new materials and techniques that support our growing operations.

The ideal candidate is equally comfortable designing tooling in CAD, troubleshooting challenges on the shop floor, and developing practical solutions that balance performance, quality, and efficiency.

Key Responsibilities

• Design and develop composite tooling, including molds, master patterns, plugs, trim and drill fixtures, bonding and assembly jigs, and handling fixtures.
• Select appropriate tooling materials and manufacturing methods based on part geometry, cure requirements, production needs, and cost.
• Develop and implement composite manufacturing processes, including prepreg and wet layup, vacuum bagging, oven and out-of-autoclave curing, resin infusion, core integration, and secondary bonding.
• Create and maintain manufacturing documentation, including ply books, cut files, layup sequences, bagging procedures, cure cycles, and standardized work instructions.
• Lead the transition of composite components from prototype to repeatable production, improving quality, efficiency, yield, and cost.
• Collaborate with design engineers on laminate schedules, ply orientations, material selection, and structural analysis to support aircraft development.
• Perform or support composite finite element analysis (FEA) and laminate calculations to inform engineering and manufacturing decisions.
• Lead Design for Manufacturing (DFM) and Design for Assembly (DFA) reviews to improve manufacturability, tooling, tolerances, and assembly processes.
• Evaluate new composite materials, tooling technologies, and manufacturing processes through research, testing, and prototype development.
• Troubleshoot manufacturing defects, conduct root-cause analysis, and implement corrective actions to improve production quality.
• Support material and process validation through test panels, coupon testing, and qualification activities.
• Coordinate with suppliers and vendors on composite materials, tooling fabrication, equipment, and outsourced components.
• Support composite shop operations, including equipment selection, facility layout, and safe material handling practices.
• Maintain accurate technical documentation and configuration control for tooling, manufacturing processes, and work instructions.
• Travel occasionally (less than 5%) to support suppliers, tooling vendors, and testing activities.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Materials Science, or a related field.
• Minimum of 5 years of engineering experience with advanced composite structures, including significant hands-on composite tooling and manufacturing experience.
• Demonstrated experience designing composite tooling and implementing it in a production environment.
• Hands-on experience with composite fabrication processes, including prepreg or wet layup, vacuum bagging, oven or autoclave curing, and resin infusion.
• Strong understanding of composite laminate design, ply orientation, stacking sequences, core materials, and structural material selection.
• Proficiency with CAD software such as SolidWorks, CATIA, or equivalent, including surface modeling and mold/tool design.
• Experience performing composite FEA or applying structural analysis results to laminate design and engineering decisions.
• Experience conducting DFM/DFA reviews and collaborating with design engineers to improve manufacturability.
• Ability to develop clear manufacturing procedures, process specifications, work instructions, and technical documentation.
• Strong analytical and problem-solving skills, with sound engineering judgment, data-driven decision-making, and a hands-on, shop-floor mindset.
• Excellent written and verbal communication skills, with the ability to collaborate proactively across design engineering and manufacturing teams.
• Ability to work independently, manage shifting priorities, and drive projects to completion in a fast-paced, experimental environment.
• Ability to work on-site in Colorado Springs, CO.
• Ability to lift up to 50 pounds.
• Ability to travel occasionally (less than 5%) to support business needs.
• Applicants must be authorized to work for any employer in the U.S. We are unable to sponsor or take over sponsorship of an employment visa at this time.

Preferred Qualifications

• Experience developing composite structures for aerospace, unmanned aircraft systems (UAS), or other weight-critical applications.
• Experience with composite design and analysis tools such as Fibersim, CATIA Composites Design, Femap/Nastran, Abaqus, or ANSYS Composite PrepPost.
• Knowledge of CMH-17 (MIL-HDBK-17), composite material allowables, and aerospace composite process specifications.
• Experience with CNC-machined tooling, computer-aided manufacturing (CAM), or CNC router programming for tooling and master patterns.
• Experience with sandwich composite construction, including honeycomb and foam cores, and bonded assemblies.
• Familiarity with nondestructive inspection (NDI) methods, including tap testing, ultrasonic inspection, and composite repair.
• Experience establishing or expanding composite manufacturing operations, including equipment selection, process qualification, and technician training.
• Familiarity with product lifecycle management (PLM), product data management (PDM), configuration control, and engineering change processes.
• Knowledge of AS9100 or comparable aerospace quality management systems.
• Experience working in a startup or rapidly evolving manufacturing environment with changing priorities and limited resources.

Our Values

Our values guide how we work with one another, support our customers, and solve challenging problems:

• People: We value relationships with our colleagues and customers while embracing and upholding the worth of every individual.
• Excellence: We have a mindset of excellence at all times.
• Accountability: We believe the foundation of trust is accountability
• Knowledge: We believe that innovation and success depend on gaining, documenting and sharing knowledge

What We Offer

At PteroDynamics, you will have the opportunity to significantly impact the future of aerial technology through creativity and innovation. The company offers a comprehensive compensation package, which includes a competitive salary, stock options, company-sponsored medical insurance, dental, vision, life insurance, 401(k) plan with company matching, long-term disability, paid time off, paid holidays, paid sick time, and a collaborative, inclusive working environment in an exciting, growing startup company.

Date the Position Closes

Applications will be accepted for 60 days beyond the posting date, or until the position is filled, whichever comes first.

Salary

$150,000 - $170,000 per year

PteroDynamics is an Equal Opportunity Employer. We prohibit unlawful discrimination against applicants or employees on the basis of age 40 and over, color, disability, gender identity, genetic information, military or veteran status, national origin, race, religion, sex, sexual orientation, or any other status protected by state or local law.

PteroDynamics will make reasonable accommodations for qualified individuals with known disabilities and employees whose work requirements interfere with a religious belief unless doing so would result in an undue hardship to PteroDynamics or a direct threat. Employees or applicants needing such accommodation are instructed to contact Human Resources immediately at [email protected] .