Materials & Process Engineer - Composites

General Dynamics Mission Systems - Marion, VA3.7

Full-timeEstimated: $80,000 - $110,000 a year
Basic Qualifications
Master’s degree in materials engineering, composites engineering, chemical engineering, mechanical engineering or a related specialized area or field is required (or equivalent experience) plus a minimum of 3 years of relevant experience or minimum 5 years with a Bachelor of Science degree.

Department of Defense Secret security clearance is preferred at time of hire. Candidates must be able to obtain a Secret clearance within a reasonable amount of time from date of hire. Applicants selected will be subject to a U.S. Government security investigation and must meet eligibility requirements for access to classified information. Due to the nature of work performed within our facilities, U.S. citizenship is required.

Responsibilities for this Position
General Dynamics Mission Systems has an immediate opening for a Materials & Process Engineer. This position provides an opportunity to further advance the cutting-edge technology that supports some of our nation’s core defense/intelligence services and systems. General Dynamics Mission Systems employees work closely with esteemed customers to develop solutions that allow them to carry out high-stakes national security missions.

Lead the development of strategic tasks or small projects by applying engineering and organizational knowledge and expertise to achieve technical goals
Understand and interpret the technical, organizational and process aspects of the tasks assigned and relate them to the technical needs of the overall project or organization
Plan and execute small projects or task elements within larger projects, organizations, or for groups of projects
Responsible for the completion of assigned engineering tasks or small projects within budgetary and scheduling guidelines
Actively identify technical and organizational risks and ensure that they are included in risk mitigation plans
Participate in development of program strategies and teaming strategies as they relate to the business
Participate in the proposal process including preparation of cost estimates and technical writing
Participate in feasibility studies and testing of new and modified designs
Travel will be required (infrequent to 10%)

Primarily create and maintain process, material, and equipment specifications including raw material specifications for composite materials such as prepregs, adhesives and various lightweight core products used in aerospace composite assemblies. Secondarily, create and maintain process, material, and equipment specifications for chemical surface treatments for adhesive bonding and coating applications.
Analyze material failure data and laboratory test results to determine causes of failure for composite products
Prepare and effectively present highly technical and complex engineering reports and estimates verbally and in writing
Participate in product qualification and testing
Support product manufacture and testing including troubleshooting and process improvement
Recommend and implement process changes to improve quality and increase yield
Assist with proposal development for legacy product areas in addition to new design & development projects
Perform technical writing for formal engineering reports including qualification and acceptance test reports
Perform chemical process design and identify quality control requirements for manufacturing of plated metallic and non-metallic substrates and surface treatment chemical process lines

Experience with a wide range of polymer matrix composite manufacturing processes including hand lay-up/autoclave cure, adhesive bonding, and resin transfer molding (RTM)
Thorough knowledge of the polymer chemistry of epoxy, bismaleimide (BMI), polyimide, and cyanate ester resins as they relate to the processing of pre-impregnated fabrics and unidirectional tapes commonly used in fiber-reinforced composite structure and adhesive systems
Experience in developing and writing process specifications and work instructions for composite fabrication operations
Experience with composites materials testing and qualification methods, both mechanical and thermal
Ability to mentor junior Materials and Processes engineers in areas of specification development and materials test execution and documentation
Solid understanding of chemical surface treatments and processes involved in both electroless plating and electroplating on non-metallic surfaces, photosensitive resist application, and metal etching in an industrial environment
Experience in implementing new processes, documentation, quality/process controls, and operator training
Ability to interpret engineering drawings and specifications
Analytic and problem solving skills
Proficient in MS Office applications – Word, Excel, and PowerPoint
Excellent verbal and written communication skills including ability to prepare and present technical briefings to senior management and customers


Experience in composites and adhesives manufacturing, materials characterization, rheology/cure dynamics and mechanical-structural testing
Ability to apply principles of chemistry, physics, and material behavior to develop metallic, non-metallic and composite material and processing specifications for fabrication and assembly processes
Familiarity with design of experiments, statistical process control (SPC), root cause & corrective action (RCCA), and failure mode and effects analysis (FMEA)
Familiarity with CNC machining, assembly, and finishing

Company Overview
General Dynamics Mission Systems (GDMS) engineers a diverse portfolio of high technology solutions, products and services that enable customers to successfully execute missions across all domains of operation. With a global team of 13,000+ top professionals, we partner with the best in industry to expand the bounds of innovation in the defense and scientific arenas. Given the nature of our work and who we are, we value trust, honesty, alignment and transparency. We offer highly competitive benefits and pride ourselves in being a great place to work with a shared sense of purpose. You will also enjoy a flexible work environment where contributions are recognized and rewarded. If who we are and what we do resonates with you, we invite you to join our high performance team!