Sigma Defense Jobs in Wisconsin (NOW HIRING)

Galvion designs, develops, and manufactures ballistic helmets and dynamic power and data management solutions for the modern battlefield. We are a passionate, global, and fast‑paced team collaborating with several strategic partners and are committed to enhancing the overall agility and survivability of the modern warfighter and tactical operator.

The Manufacturing Engineer IV is responsible for leading and optimizing the production of ballistic helmets and advanced protective systems in a regulated defense manufacturing environment. This role focuses on improving manufacturing processes for advanced composite materials, ensuring consistent ballistic performance, increasing production efficiency, and maintaining strict quality and compliance standards. The position supports production scaling, continuous improvement initiatives, cross‑functional collaboration, and the delivery of mission‑critical protective equipment for military and law enforcement applications.

• Develop, refine, and standardize manufacturing processes for ballistic helmet production (layup, molding/pressing, trimming, finishing, coating)
• Optimize cycle times, material utilization, and yield while maintaining ballistic integrity
• Lead root cause analysis for defects such as delamination, voids, dimensional non‑conformance, or coating failures
• Define and control critical process parameters (temperature, pressure, cure time, consolidation)
• Partner with R&D on material selection, qualification, and process transfer
• Support new product introduction (NPI) and transition from prototype to full‑rate production
• Design and implement tooling, fixtures, and work instructions for repeatable manufacturing
• Balance throughput with strict compliance to ballistic performance standards
• Implement SPC and process controls for safety‑critical features
• Support ballistic testing, lot acceptance, and failure investigations
• Specify and improve equipment such as presses, ovens, automation equipment, and final assembly lines
• Evaluate automation opportunities in material handling, cutting, painting and finishing operations
• Improve equipment uptime and preventive maintenance strategies
• Mentor technicians and junior engineers in best manufacturing practices
• Contribute to capacity planning, cost reduction strategies, and long‑term manufacturing roadmap

Required

• Bachelor’s degree in Mechanical, Materials, Industrial Engineering, or related field
• 8–12+ years of manufacturing engineering experience in composites, defense, aerospace, or protective equipment
• Hands‑on experience with molding, pressing, or composite fabrication processes
• Strong understanding of process control in safety‑critical manufacturing
• Experience with root cause analysis and continuous improvement methods
• CAD Experience Preferred
• PLC Logic Understanding
• Deep process ownership mindset in a safety‑critical environment
• Ability to balance throughput, cost, and uncompromising quality
• Strong analytical and problem‑solving capability (especially with materials/process interactions)
• Leadership and influence across production teams

• Experience with ballistic materials (aramids, UHMWPE, hybrid composites)
• Familiarity with defense contracting requirements and documentation
• Lean / Six Sigma certification (Green or Black Belt)

Galvion provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, gender, sexual orientation, gender identity or expression, national origin, age, disability, genetic information, marital status, amnesty, or status as a covered veteran in accordance with applicable federal, state and local laws. Galvion complies with applicable state and local laws governing non‑discrimination in employment in every location in which the company has facilities. This policy applies to all terms and conditions of employment, including, but not limited to, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.