Senior Composites Manufacturing Engineer

Job Description

Job Description

The Opportunity

Own the composite core pultrusion process at TS Conductor. You will lead process improvement for the core of our advanced overhead conductors, working hands-on with Production, Quality, Maintenance and R&D to improve product consistency, raise throughput, reduce scrap and scale up manufacturing.

Why you will want this job:

• Real ownership: The pultrusion process parameters are yours to optimize, from fiber tension to pulling speed.
• Visible impact: Your results show up in yield, throughput, scrap and process capability.
• Room to build: You support equipment upgrades, new line commissioning and production scale-up.
• Influence: You partner with Quality and R&D to connect process conditions to composite performance.
• Hands-on work: You spend your time on the shop floor, where the process is won.

What You Will Own

You own the pultrusion process and its results. Each area below states the outcome you are accountable for, followed by how you will deliver it.

• 1. Process Performance

  Your outcome: The pultrusion process runs stable and capable, with higher yield and throughput, less scrap and better material utilization.

  • Own and optimize process parameters, including fiber tension and alignment, resin impregnation, die temperature profiles, cure conditions and pulling speed.
  • Use production data, statistical process control and designed experiments to improve yield, throughput, process capability and material utilization.
• 2. Root Cause and Prevention

  Your outcome: Production defects and process instability are traced to their root cause and fixed so they do not come back.

  • Troubleshoot defects and instability, identify root causes and implement corrective actions that prevent recurrence.
• 3. Trials and Qualification

  Your outcome: Every change to fibers, resins, sizing, tooling or process is proven in a trial and turned into a stable production practice.

  • Plan and run trials to evaluate fibers, resin systems, sizing compatibility, tooling and process changes.
  • Partner with Quality and R&D to connect process conditions to mechanical and thermal performance, and support material and process qualification.
• 4. Standards, People and Scale-Up

  Your outcome: Production teams run to clear, current standards, and new equipment and lines come online safely and on plan.

  • Develop and maintain process specifications, operating procedures, control plans and troubleshooting guides, and train and coach production teams.
  • Support equipment upgrades, new line commissioning and production scale-up while maintaining safe material handling and operating practices.

What You Bring

• Required:
  • 5+ years in composite manufacturing, with hands-on responsibility for process engineering, troubleshooting or production improvement.
  • Strong understanding of fiber-reinforced polymer composites, resin processing, cure behavior, and how processing affects material properties.
  • A track record of solving manufacturing problems with data, structured root cause analysis and practical shop-floor experimentation.
  • Ability to lead improvement projects and communicate effectively with operators, engineers, suppliers and cross-functional teams.

• Preferred:

  • Master's or advanced degree in Materials Science, Materials Engineering, Polymer Science or a related engineering discipline.
  • Direct pultrusion experience, particularly with continuous carbon fiber and thermoset resin systems.
  • Experience with composite characterization, mechanical testing, thermal analysis, and Lean or Six Sigma methods.

What We Offer

• Medical, dental, life insurance and long-term disability, starting the first of the month after 30 days of employment.
• Paid time off (sick and vacation), 10 company holidays, and a 401(k) with company match.
• Referral rewards program.

Work Environment

You will work across the office, the lab and safety-sensitive manufacturing areas, spending much of your time on the shop floor near large-scale production equipment, observing processes and working with production teams.

• Support R&D and Quality Control Testing by designing new manufacturing processes, tests and experiments that improve product design, production methods, quality and standards compliance.
• In the quality lab, test, document and analyze data to improve production lines, write instructions and collaborate with others.
• Make occasional on-site visits to suppliers, vendors or customers to review quality issues or assess material and tooling performance.
• Follow occupational health and safety practices at all times, which are essential in our manufacturing environment.