Principal Engineer Special Processes

ABOUT THE ROLE
The Special Processes Manager is responsible for leading the greenfield setup, equipment investment, and process development of aerospace special process capabilities—including shot peening, thermal spray coatings, heat treatment, brazing, surface preparation, and chemical processing—supporting the company's propulsion programs, including turbofan, microjet, and piston engines.
This role leads New Product Introduction (NPI), industrialization, and serial production readiness for special processes performed in-house, working in close collaboration with design engineering, quality, supply chain, internal and external partners, equipment vendors, and technology providers. The position plays a key role in design-to-manufacture and concurrent engineering activities, ensuring robust, cost-effective, and NADCAP-compliant special process capability.

RESPONSIBILITIES
Manufacturing Strategy, Greenfield Facility & Equipment Investment

• Lead the greenfield establishment of in-house special process capabilities, including facility layout, equipment specification, supplier selection, commissioning, and process qualification.
• Define equipment requirements, utility needs, process controls, and environmental requirements for new special process cells.
• Lead make-versus-buy evaluations and phased capability development strategies aligned with product and production roadmaps.
• Develop capital investment plans for special process equipment, tooling, and automation.
• Coordinate technology transfer activities from external partners and suppliers into the company's manufacturing operations.

Special Process Development & Industrialization

• Lead the development, qualification, and continuous improvement of aerospace special processes for rotating, structural, and hot-section engine components.
• Provide technical leadership across processes including shot peening, thermal spray coatings (HVOF, plasma spray, wear-resistant and environmental coatings), heat treatment (vacuum heat treatment, solution treatment, aging, and stress relief), brazing, surface preparation, grit blasting, masking, cleaning and chemical processing.
• Define and approve manufacturing routings, process specifications, work instructions, and control plans.
• Establish process capability requirements and statistical monitoring methods to ensure stable and repeatable production performance.

NPI & Program Execution

• Lead special process engineering activities during New Product Introduction (NPI) from prototype development through production readiness.
• Direct manufacturing planning, process qualification, and production ramp-up activities for new engine programs and component families.
• Own the special process focal point role for assigned engine modules, components, and development programs.
• Ensure process readiness aligns with program schedules, quality requirements, and certification objectives.

Design-to-Manufacture & Concurrent Engineering

• Lead concurrent engineering activities with design teams to ensure components are optimized for manufacturability, process capability, durability, and cost.
• Provide technical input during design reviews, material selection activities, tolerance allocation, and coating requirements.
• Identify and mitigate manufacturing and process qualification risks early in the product development lifecycle.
• Direct development of process specifications and special process requirements for new component designs.

Supplier & Partner Development

• Develop and technically support external special process suppliers, subcontractors, and manufacturing partners.
• Lead supplier capability assessments, technical audits, qualification activities, and process improvement initiatives.
• Drive resolution of process-related technical issues across the supply chain.

Cost, Performance & Continuous Improvement

• Lead special process cost estimation, tracking, and improvement initiatives.
• Identify opportunities for cycle time reduction, yield improvement, and cost competitiveness.
• Drive implementation of best-in-class aerospace special process practices, digital tools, and continuous improvement systems.

Leadership & Governance

• Build, lead, and mentor the special processes engineering team, including engineers and technicians.
• Develop training, certification, and skill development programs.
• Ensure compliance with aerospace quality system requirements and special process accreditation activities, including NADCAP readiness and compliance.

BASIC QUALIFICATIONS

• Bachelor’s or Master’s degree in Mechanical Engineering, Materials Engineering, Aerospace Engineering, Manufacturing Engineering, or a related discipline.
• 10+ years of experience in aerospace or propulsion manufacturing, with significant experience in special process development and industrialization.
• Proven experience in greenfield setup, capital investment, and industrialization of special process capability.
• Strong hands-on expertise in at least two or more of the following aerospace special process technologies: shot peening, thermal spray coatings, heat treatment, brazing, chemical processing.
• Demonstrated leadership in NPI and concurrent engineering environments.
• Experience developing process specifications, qualification plans, control plans, and process validation documentation.
• Working knowledge of aerospace materials including titanium alloys, nickel-based superalloys, stainless steels, aluminum alloys, and high-temperature materials.
• Familiarity with aerospace quality systems, process qualification methodologies, and special process accreditation requirements (NADCAP).
• Experience leading teams and working with internal stakeholders, external manufacturing partners, and capital investment projects.
• Ability to work effectively with design, quality, operations, supply chain, partners, and equipment vendors in a concurrent engineering environment.

PREFERRED QUALIFICATIONS

• Master’s degree in Mechanical Engineering, Materials Engineering, Aerospace Engineering, Manufacturing Engineering.
• 12 + years of experience in aerospace or propulsion manufacturing, with significant experience in special process development and industrialization.
• Proven experience in greenfield setup, capital investment, and industrialization of special process capability.

WHY CHOOSE THE COMPANY
At the company, the real investment goes beyond compensation. Through our dedicated learning academy and digital learning platforms, employees have access to extensive opportunities to develop new skills, deepen their expertise, and advance their careers. Combined with the freedom to innovate, strong career support, and the opportunity to collaborate with world-class talent from across the globe, the company is a place where you can continue to grow, keep learning, and turn ambitious ideas into meaningful outcomes.
Working at the company also comes with a package that genuinely reflects how much we value our people. Salaries are highly competitive and tax-free and, depending on your role and seniority, benefits can include family visas, annual flight tickets, medical insurance for you and your dependents, and education allowances for your children.