Lead Engineer, Materials & Process

Mountain View, CA
Cora – Composites Materials and Process Engineering
Full-time
Here at Kitty Hawk, where a century of aviation practices meets technology breakthroughs and a world-class engineering team, things are looking up. In 1903, the Wright brothers took flight for the first time from the beaches of Kitty Hawk, North Carolina. Our journey started by designing, testing and building all-electric vertical take-off and landing products for work and play. Today, in California, we are building on the Wright Brothers’ legacy to create the next generation of vehicles for everyday flight.

Cora began as a dream. A self-piloting air taxi so personal and so simple it could take the trips we make everyday, the ones that define our lives, and bring them to the sky. We’ve been at work on Cora since 2010, tackling some of the biggest challenges in aviation. Today, that dream is one step closer. Join us in making that dream a reality.

We are seeking a Lead Engineer, Materials and Process to support the design, manufacture, and inspection of primary structural components for our vehicle.  You will lead a small team and work closely with designers, analysts, manufacturing engineers, and techs as part of our design and production team.

Responsibilities:

    • Direct management of 3-5 engineers and technicians
    • Documenting material specifications for composites and adhesives
    • Developing and implementing composite material manufacturing processes and non-destructive inspection methods
    • Authoring material qualification plans, process specifications, and mechanical test plans to develop and document composite material properties and allowables
    • Developing processes for adhesive bonding and fasteningSupporting quality control standards by developing inspection methods and procedures
    • Performing and supporting mechanical testing of structural coupons and elements
    • Providing support for manufacturing engineers and technicians, including training as required
    • Researching new materials and processesSupporting design, test, and flight readiness reviews
    • Dispositioning non-conformances and updating processes to reduce frequency
    • Developing methods for field inspections and repairs

Within 3 months you will:

    • Get to know the team
    • Shadow design engineers, manufacturing engineers, and technicians to become familiar with our aircraft, materials, and processes
    • Become fluent in our CAD and PLM tools
    • Become familiar with our current capabilities for testing and inspection

Within 6 months you will:

    • Work with technicians and manufacturing engineers to develop manufacturing processes, tooling, procedures, quality control points, inspection plans, etc.
    • Take ownership of processes documentation
    • Work with technicians and manufacturing engineers to develop manufacturing processes, tooling, procedures, quality control points, inspection plans, etc.
    • Start working solutions to non-destructive inspections

Within 12 months you will:

    • Reach a high level of familiarity with the aircraft and manufacturing processes
    • Continuously improve manufacturability and performance
    • Efficiently incorporate design changes into manufacturing procedures

Required:

    • Bachelor's degree in Mechanical or Aerospace Engineering or related Science
    • 5+ years of experience as a M&P Engineer in an aerospace (or similar) production environment, preferably in a fast-paced small R&D environment
    • Experience implementing non-destructive inspection methods such as thermography and ultrasonic inspection
    • Familiarity with traditional aerospace composite manufacturing techniques (prepreg, cores, adhesives)
    • Experience supporting engineering team with specification, process, and test documentation
    • Experience with CAD software such as Solidworks, CATIA, NX, or similar

Desired:

    • Hands on composite fabrication experience
    • Experience with out-of-autoclave hand lay-up techniques with thermoset composite materials and bonding
    • Experience with developing and documenting processes that result in high-performing composite primary structures
    • Experience with mechanical testing of structural coupons and elements
We are located in Mountain View just a couple of hundred feet from Shoreline Lake and its surrounding walking/jogging trails. We offer a comprehensive benefits package including medical, dental, vision and life insurance (company pays 100% of employee premium), unlimited PTO days, 10 company holidays, a 401(k) plan with 50% company matching (no vesting period), commuter assistance, and education assistance. And on top of all that, we also offer a variety of perks such as free catered lunches, flight lessons, gym membership subsidies, snacks, drinks, fruits, employee referral bonus, charitable giving match, IP bonus program, happy hours and many more.

Kitty Hawk provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability or genetics. In addition to federal law requirements, Kitty Hawk abides by applicable state and local laws governing nondiscrimination in employment in every location in which the company has facilities. This policy applies to all terms and conditions of employment, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation and training.

Kitty Hawk is an E-Verify employer.