Manufacturing Engineer - Composites

The role and your team:  

We are looking for an ambitious and experienced technology expert to join our team! In this role, you will be the technical expert for composite manufacturing, characterization, and qualification processes both within the Lilium factories and within the global supply chain. 

Your experience and expertise will be called upon to develop and deploy controlled processes in use throughout the structural components of our Lilium Jet. When working with our supply base, you will be instrumental in leading the industrialisation of our external partners to meet our vision.  This includes the development of new components and assemblies, taking them through to stable production, following industry-standard structured approaches including APQP. To build up essential technical capabilities within Lilium, you will follow a rigorous approach to establishing the correct process parameter windows to meet engineering intent for building of development hardware, create prototypes and coupon-level hardware samples and data packages for technical approval, and create technical documentation for the smooth operation and control of our production equipment.  

You will own end-to-end delivery of advanced aerostructures components in keeping with our design and Materials and Process specifications and engage in design-for-manufacture topics to assure successful delivery to program. You will work with materials characterization technologies, perform microscopy, run panel-scale materials qualification trials, perform critical analysis of supplier processes, guide special process approval in multiple locations, guide first-part qualification, all in collaboration with design engineering, procurement, and supply chain operations stakeholders.

This role will require travel to supplier sites at least 20% of the time. 

Your Day to Day PE Composites: 

• Enforce Design for Manufacture with your design team to enable the goal of high rate, cost effective manufacturing and be the voice of manufacturing in which suppliers we partner with for your product group. 
• Develop, drive and deliver all technical aspects of the industrialisation road map with our suppliers on within Lilium, enforcing clear collaboration between the respective parties to secure delivery against business case cost & quality targets. 
• Develop and establish material control methods to ensure material integrity prior to being included in our processes, and advise the supply base on tooling solutions required to meet rapid program timelines. 
• Design and create appropriate test sample geometry and accompanying process windows to support technical plan milestone achievements in collaboration with Engineering and Test functions 
• Use a structured process to assure consistent, well-controlled laboratory operations within a dynamic production environment, and enable fast, clear decision making with suppliers when establishing the improvement actions necessary to prevent common recurrences.
• Qualify special processes by performing a wide range of destructive characterization operations and generate vital technical data showing material conformance, and reviewing the same technical data with the supply base in collaboration with quality and design stakeholders
• Use a structured process to assess technical feasibility, producibility, and manufacturability of cure and moulding technology applications on aircraft parts
• Create and review technical plans detailing tooling, process, process control methods, and sample characterisation to support fixed process approval
• Write process and technical specifications for ASTM-compliant characterization operations, train technicians and deploy technology as required, and execute characterization work when necessary to support product and process development milestones.
• You will make use of PPAP processes to secure delivery of hardware, and guide the Manufacturing Readiness Level (MRL) growth of our on-site and supply chain capabilities 

Your Profile: 

• Mechanical, Materials, or Chemical Engineering, or Industrial-related Master’s Degree, or graduate of manufacturing apprentice program combined with Bachelor’s degree 
• Minimum of 8 years of experience in composite manufacturing with experiences ranging from materials qualification to supplier support and product fulfilment 
• Strong technical expertise in composite aerostructure materials manufacturing and characterization, document writing, and sample control 
• Demonstrable experience operating alone in supplier facilities, with strong communication skills that support the working practices of local management to technical personnel. 
• Experience developing, maintaining, and leading strong, collaborative relationships with design teams, equipment manufacturers, and component suppliers.
• Demonstrated impact and experience in design for manufacturing and design for assembly activities focused on composite components 

• Strong organizational capability with continuous attention to maintaining well-controlled lab operations, including 5S control of lab environment, tool and consumable monitoring, and continuous improvement 
• Excellent analytical capabilities, written communication, and verbal communication to solve problems with urgency and collaborate with varied technical audiences. 
• Practical Experience with PPAP / APQP processes highly desired; Six Sigma DFSS/DMAIC Green Belt certification or higher desired