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Composites Manufacturing Engineer

Santa Ana, CA
  • Posted: over a month ago
  • Full-Time
Job Description

Company Overview:

At Overair, we are dedicated to bring next generation sustainable air transportation to everyone.  Our answer is Butterfly, an all-electric vertical takeoff and landing (VTOL) aircraft designed to safely and affordably carry passengers over traffic and congestion.  Butterfly leverages over two decades of VTOL aircraft development, patented VTOL technology, and flight vehicle experience. 

Overair believes in the lofty goals of sustainable air mobility and we are committed to solving the hard challenges along the way.  We are building an industry leading team covering an expanse of skills, talents, and expertise in order to build a superior electric VTOL aircraft.  If you enjoy solving difficult problems, and seeing your ideas and visions expressed in flight hardware, we want you on our team.

Job Overview:

Overair is seeking an experienced Composites Manufacturing Engineer to take ownership of helping to manufacture a significant number of parts in the composite airframe and propulsion systems. Qualified candidates will be responsible for supporting the initial component builds and assembly of Overair's Butterfly Electric Vertical Take Off and Landing aircraft. Following components through their initial prototype phase all the way through assembly and vehicle integration.

Roles and Responsibilities:

  • Work closely with aircraft structures design engineers to provide manufacturing input during initial design stages.
  • Design tooling for lamination, trim, and assembly operations, as well as manufacturing aids to help with day-to-day production; this includes conceptualization, material selection, vendor sourcing and final inspection.
  • Develop composite processing techniques utilizing new approaches, materials, and tooling methods.
  • Develop ply patterns (splicing, overlaps, staggers, flat patterns, .dxf exports, etc.) using CATIA's Composite Workbench.
  • Create laser ply projection files for composite lamination builds.
  • Support shop floor operations by working with continuous support of shop floor operations and oversight & programming of composite related equipment (laser projectors, ply cutting table, autoclaves, ovens and other auxiliary equipment).
  • Assist composite technicians and clearly communicating design expectations.
  • Design, set-up, and dimensionally inspect/interrogate assembly fixturing to support locating and bonding & fastening of large, complex, primary structure.
  • Investigate root cause of failures or quality issues; develop go-forward approach.
  • Interface with fellow manufacturing engineers, structures design engineers, engineering management, operations, shop floor personnel, and external vendors.

Required Qualifications:

  • Minimum of 4 years of professional industry experience.
  • Undergraduate or graduate degree in Aerospace, Mechanical Engineering or similar.
  • Hands-on experience with composites materials and processing, exhibiting strong fabrication and assembly skills (demonstrated through past work or experience via a student team, internship, or personal project).
  • Previous experience manufacturing a full vehicle including component and assembly levels with exposure to integration efforts.
  • Understanding of composite part design, material properties, allowables and testing.
  • Proficient with solid modeling and surfacing in 3D CAD Software.
  • Strong communication and inter-personal skills.

Desired Qualifications:

  • Experience using CATIA V5/V6 and 3DExperience Software Suite.
  • Experience using CATIA's Composite Workbench or FiberSim NX.
  • Experience programming and handling autoclaves & ovens, laser projection systems, ply cutters, laser trackers and other dimensional inspection equipment.
  • Experience with composite inspection (NDI) techniques and methods.
  • Experience with high-rate composites manufacturing methods (fiber placement, resin transfer molding, compression molding, thermoplastics).

Summary of Benefits:

  • Medical – Company provides no cost Medical coverage for employee and all dependents.
  • Dental & Vision – Company pays for 80% of Dental and Vision coverage for employee and 50% for each dependent.
  • 401(k) plan – Employee eligible on first day of work, 6% Company-match, no vesting period.
  • 12 weeks of supplemental Paid Family Leave
  • Company-paid Life Insurance plan.
  • Paid Time Off:
    • Vacation: 4 weeks/year
    • Holiday: 10 days/year
    • Sick Time: 48 hours/year



Santa Ana, CA



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