Senior Engineer - Special Processes (Aerospace)

About the role

The Special Processes Senior Engineer is a senior technical and team-leading role at EDGE's Powertech business, based in Abu Dhabi. The engineer develops, qualifies and industrializes critical aerospace special processes for propulsion programs covering turbofan, microjet and piston engines. The role acts as technical authority for special process technologies, supports greenfield manufacturing setup, New Product Introduction (NPI), production industrialization and process capability development, and provides day-to-day technical leadership to engineers and technicians.

Key responsibilities

• Lead development, qualification and continuous improvement of special processes for rotating, structural and hot-section engine components, including 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 and statistical monitoring.
• Lead process validation: First Article Inspection (FAI), industrial qualification, capability studies and production readiness reviews.
• Support greenfield special process capability, including facility layout, equipment specification, supplier selection, commissioning, technology transfer and make-versus-buy decisions.
• 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.
• Oversee suppliers and partners, lead supplier process reviews, technical audits and qualification, and resolve 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.
• 8+ years in aerospace manufacturing, with significant experience in special process development and industrialization; preferred 12+ years.
• Hands-on expertise in at least two special processes such as shot peening, thermal spray coatings, heat treatment and brazing.
• Experience with NPI, process qualification, control plans and validation documentation.
• Ability to work with design, quality, operations, supply chain and vendors in a concurrent engineering environment.

Required skills

• Working knowledge of aerospace materials: 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 (e.g., NADCAP).