Senior Engineer - Special Processes

About the role

EDGE, an advanced technology group based in Abu Dhabi, is hiring a Senior Engineer Special Processes. This is a senior technical and team-leading role responsible for developing, qualifying and industrializing critical aerospace special processes supporting Powertech's propulsion programs, including turbofan, microjet and piston engines. The engineer acts as technical authority for special process technologies, supports greenfield manufacturing setup, New Product Introduction (NPI), production industrialization and process capability development, and leads the special processes team alongside Manufacturing Engineering, Design Engineering, Quality, Supply Chain, suppliers and equipment vendors.

Key responsibilities

• Lead development, qualification and continuous improvement of special processes for rotating, structural and hot-section engine components, covering shot peening, thermal spray coatings (HVOF, plasma spray), heat treatment, brazing, surface preparation, cleaning and chemical processing.
• Define manufacturing routings, process specifications, work instructions, control plans and acceptance criteria, and set up process capability requirements and statistical monitoring.
• Lead process validation including First Article Inspection (FAI), industrial qualification, capability studies and production readiness reviews.
• Support greenfield manufacturing setup, including facility layout, equipment specification, supplier selection, commissioning, make-versus-buy decisions and technology transfer.
• Lead special process engineering during NPI, from prototype through production ramp-up, and act as focal point for assigned engine modules and programs.
• Work with design teams on concurrent engineering, design reviews, material selection, tolerance allocation and risk mitigation.
• Provide technical oversight to suppliers and subcontractors, lead supplier process reviews, audits and qualification, and drive resolution of process issues across the supply chain.
• Mentor and guide special process engineers and technicians.

Required profile

• Bachelor's or Master's degree in Mechanical, Materials, Aerospace or Manufacturing Engineering or a related discipline.
• 8+ years of experience in aerospace manufacturing, with significant experience in special process development and industrialization; preferred 12+ years.
• Proven experience in aero-engine NPI, process qualification, equipment trials, commissioning and manufacturing readiness.
• Experience developing process specifications, qualification plans, control plans and validation documentation.
• Ability to work with design, quality, operations, supply chain, partners and vendors in a concurrent engineering environment.

Required skills

• Hands-on expertise in at least two special processes such as shot peening, thermal spray coatings, heat treatment and brazing.
• Working knowledge of aerospace materials including titanium alloys, nickel-based superalloys, stainless steels and aluminum alloys.
• Familiarity with aerospace quality systems, process qualification methodologies and special process accreditation requirements (e.g., NADCAP).