Principal Engineer – Special Processes

About the role

The Special Processes Manager will lead the greenfield establishment, equipment investment and process development of aerospace special process capabilities supporting Powertech’s propulsion programs. This senior engineering position oversees New Product Introduction, industrialisation and serial production readiness, ensuring robust, cost‑effective and NADCAP‑compliant processes.

Key responsibilities

• Lead greenfield setup of special process facilities, including layout, equipment specification, supplier selection, commissioning and qualification.
• Define equipment, utility, process control and environmental requirements for new process cells and develop capital investment plans.
• Develop, qualify and continuously improve aerospace special processes such as shot peening, thermal spray coatings, heat treatment, brazing and chemical processing.
• Drive NPI activities from prototype through production readiness, managing manufacturing planning, process qualification and ramp‑up.
• Collaborate with design teams to optimise manufacturability, provide technical input during design reviews and mitigate process risks.
• Support and audit external suppliers, lead capability assessments and resolve technical issues across the supply chain.
• Lead cost estimation, tracking and continuous improvement initiatives for special processes.
• Build and mentor a special processes engineering team, ensuring NADCAP readiness and compliance.

Required profile

• Bachelor’s or Master’s degree in Mechanical, Materials, Aerospace or Manufacturing Engineering.
• 10+ years of aerospace or propulsion manufacturing experience with a focus on special process development and industrialisation.
• Proven experience in greenfield setup, capital investment and NPI environments.
• Strong hands‑on expertise in at least two of the following: shot peening, thermal spray coatings, heat treatment, brazing, chemical processing.
• Demonstrated leadership in concurrent engineering and cross‑functional collaboration.

Required skills

• Shot peening
• Thermal spray coatings (HVOF, plasma spray)
• Heat treatment (vacuum, solution, aging, stress relief)
• Brazing
• Chemical processing
• Process qualification and control plan development
• NADCAP accreditation knowledge
• Aerospace materials knowledge (titanium alloys, nickel‑based superalloys, stainless steels, aluminum alloys)