Director of Advanced Manufacturing Engineering, Materials & Processes

Job Description:

As Director of Advanced Manufacturing Engineering, Materials & Processes, you’ll provide leadership for all manufacturing engineering activities with a strong focus on cold spray process development, optimization, and scaling. You’ll lead a team of engineers while collaborating closely with R&D, quality, production, and business development to deliver repeatable, high-quality components that meet stringent aerospace and defense standards.

This is a hands-on senior leadership role reporting directly to the COO. We need someone who can bridge advanced materials knowledge with real-world production execution in a fast-paced, growing environment.

Key Responsibilities:

· Lead the development, optimization, and qualification of cold spray processes—including parameter development, powder feedstock selection, nozzle design, robotic programming, and deposition strategies—to achieve target density, adhesion, mechanical properties, and deposition efficiency.

· Drive continuous improvement across the manufacturing floor using lean principles, Six Sigma, and statistical process control to reduce cycle times, minimize scrap, and improve overall efficiency and cost competitiveness.

· Build, mentor, and develop a high-performing team of manufacturing, process, and materials engineers.

· Partner with R&D to successfully transition new alloys, materials, and applications from development into qualified, full-rate production.

· Own robust manufacturing documentation, process controls, PFMEAs, control plans, and validation activities to ensure compliance with AS9100, ITAR/EAR, and customer requirements.

· Evaluate and implement automation, robotics, in-situ monitoring, and other advanced technologies to enhance capability and throughput.

· Serve as the primary manufacturing technical authority in customer audits, program reviews, and new business development efforts.

· Manage budgets, capital equipment plans, and key projects with a strong focus on delivering measurable results.

Position Requirements:

· Bachelor’s degree in Materials Science, Metallurgy, Materials Engineering, Mechanical Engineering, or a closely related field (Master’s or PhD preferred).

· 10+ years of progressive experience in manufacturing engineering or process development within aerospace, defense, or advanced materials industries.

· Strong background in materials science or metallurgy, including powder characterization, microstructural analysis, and mechanical testing.

· Proven experience leading and developing engineering teams in a production setting.

· Solid understanding of cold spray technology or similar solid-state additive manufacturing processes (direct cold spray experience strongly preferred).

· Working knowledge of aerospace quality systems (AS9100, Nadcap) and ITAR/EAR requirements.

· Ability to work with diverse team and coordinate priorities based on program schedules and requirements.

· Strong communication skills and ability to provide leadership with updates on a regular cadence.

· Familiarity working in ERP systems and utilizing data for management of the organization.

· U.S. citizenship without dual citizenship required.

Preferred Qualifications:

· Hands-on experience with cold spray or additive manufacturing systems in a production or scaling environment.

· Background in cold spray repair and refurbishment applications for aerospace components.

· Familiarity with complementary processes such as CNC machining, heat treatment, NDT, and surface finishing.

· Six Sigma Green Belt or Black Belt certification.

· Experience implementing automation and Industry 4.0 tools in additive manufacturing.

·

Pay: From $130,000.00 per year

Benefits:

• 401(k)
• 401(k) matching
• Flexible schedule
• Health insurance
• Paid time off
• Parental leave
• Retirement plan
• Vision insurance

Application Question(s):

• Do you have a Bachelor’s degree in Materials Science, Metallurgy, Materials Engineering, Mechanical Engineering, or a closely related field?

• Do you have 10+ years of progressive experience in manufacturing engineering or process development within aerospace, defense, or advanced materials industries?
• Do you have a strong background in materials science or metallurgy, including powder characterization, microstructural analysis, and mechanical testing?
• Do you have a solid understanding of cold spray technology or similar solid-state additive manufacturing processes (direct cold spray experience strongly preferred)?

Ability to Commute:

• Madison, AL 35756 (Preferred)

Work Location: In person