Director Process Development Jobs in Huntsville, AL

The Thermal Spray Manager leads the day-to-day operations of the thermal spray department, overseeing all coating processes including HVOF (High-Velocity Oxygen Fuel), plasma spray, twin-wire arc, flame spray, and cold spray. This role is responsible for the safe, efficient, and high-quality production of coated components that meet customer specifications, regulatory requirements, and industry standards such as AMS, NADCAP, and AS9100.

The manager directs technical staff, drives continuous improvement, manages equipment and consumables, and serves as the technical authority for coating development, qualification, and troubleshooting. This position requires a balance of hands-on technical expertise, leadership skills, and business acumen to deliver results in a fast-paced manufacturing environment.

• Plan, schedule, and direct all thermal spray production activities to meet ontime delivery, quality, and cost targets.
• Oversee daily operations of HVOF, plasma, arc, flame, and cold spray equipment, ensuring optimal throughput and uptime.
• Monitor key performance indicators (KPIs) including yield, scrap, rework, OEE, and labor efficiency, taking corrective action as needed.
• Coordinate with masking, blasting, machining, grinding, robot programming, and inspection teams to ensure smooth workflow across the value stream.
• Manage department budget, including labor, consumables (powders, wires, gases), tooling, and capital expenditures.

Technical Leadership & Process Development

• Serve as the subject matter expert for thermal spray processes, coating chemistries, and surface preparation techniques.
• Develop, qualify, and validate new coating processes and parameter sheets in accordance with customer and industry specifications (e.g., AMS 2447, AMS 2437, AMS 2435).
• Lead troubleshooting of coating defects such as porosity, oxide content, bond strength, hardness, and dimensional issues.
• Determine or review robot or CNC part paths
• Drive process improvements through Design of Experiments (DOE), SPC, and root cause analysis using tools such as 8D, 5Why, and Ishikawa.
• Evaluate, select, and qualify new equipment, powders, wires, and gases to expand technical capabilities.
Quality, Compliance & Safety
• Ensure all coatings meet customer specifications, drawings, and applicable industry standards including NADCAP, AS9100, and AMS.
• Partner with Quality Assurance on firstarticle inspections, PPAP, FAI, metallographic evaluations, and customer audits.
• Partner with facilities in calibration, preventive maintenance, and configuration control of all thermal spray equipment, robots, and ancillary systems.
• Champion a strong safety culture by enforcing PPE use, lockout/tagout, hot work, confined space, and respiratory protection programs.
• Ensure compliance with OSHA, EPA, and local environmental regulations regarding overspray collection, dust management, and hazardous materials handling.
Team Leadership & Development
• Recruit, train, mentor, and evaluate thermal spray technicians, operators, and lead personnel.
• Develop and maintain operator certification and training programs aligned with NADCAP and customer requirements.
• Set clear performance expectations, conduct performance reviews, and foster a culture of accountability and continuous learning.
• Plan staffing levels and shift coverage to support production demand and crosstraining.
Customer & Cross-Functional Collaboration
• Interface with customers on technical reviews, coating selection, source inspections, and corrective actions.
• Support sales and estimating teams with quoting, capability assessments, and feasibility studies for new programs.
• Collaborate with Engineering, Quality, Maintenance, and Supply Chain to support new product introduction and program transitions.

Required Qualifications

Education & Experience
• Bachelor's degree; equivalent combination of education and experience will be considered.
• Minimum seven to ten years of progressive experience in thermal spray operations, painting, welding or additive manufacturing, with at least 3 years in a supervisory or management role.
• Demonstrated handson expertise with multiple thermal spray processes (HVOF, plasma, arc, flame, and/or cold spray), painting, welding, or proficiency with robot use
• Experience in manufacturing, defense and aerospace environments strongly preferred.
Technical Skills
• Strong working knowledge of AMS, NADCAP AC7109, AS9100, and customer specifications.
• Proficiency in reading engineering drawings, GD&T, and coating process specifications.
• Familiarity with robotic spray programming and PLCcontrolled spray systems.
• Working knowledge of Lean Manufacturing, Six Sigma, 5S, and continuous improvement methodologies.
• Proficient with ERP/MES systems and Microsoft Office (Excel, Word, PowerPoint).
Leadership & Soft Skills
• Proven ability to lead, develop, and motivate a technical workforce.
• Strong analytical, problemsolving, and decisionmaking skills.
• Excellent written and verbal communication skills, with the ability to present to customers, executives, and shopfloor teams.
• Sense of urgency, ownership mindset, and ability to manage multiple priorities under pressure.
Preferred Qualifications
• Bachelor’s degree in Mechanical, Industrial or Manufacturing engineering, Materials Science, Metallurgy, or related discipline.
• Six Sigma Green Belt or Black Belt certification.
• Experience leading NADCAP audits and customer source inspections.
• Experience with coating R&D, including powder development and equipment trials.

Physical Requirements & Work Environment

• Work is performed in a manufacturing environment with exposure to noise, dust, fumes, heat, and moving machinery; appropriate PPE is required.
• Must be able to stand and walk for extended periods, lift up to 40 lbs, and access elevated platforms or confined work areas as needed.
• May require occasional travel (up to 10%) for customer visits, training, audits, and supplier evaluations.
• Some flexibility to support offshifts, weekends, or extended hours during critical production periods.