Principal Composites Engineer
Senior Staff / Principal Composites Engineer
Location: Dayton, OH (In‑Person)
Employment Type: Full‑Time
Reports To: VP of Programs
Clearance: Ability to obtain and maintain a U.S. Government security clearance required
About the Role
Hawthorn Aero, Inc. is seeking an experienced Senior Staff or Principal Composites Engineer to lead advanced materials and process development in support of aerospace and defense programs. This role is ideal for a highly technical, hands‑on engineer who thrives in a collaborative environment and enjoys working closely with manufacturing, quality, and design teams to bring complex composite structures from concept to production. The Senior Staff or Principal Composites Engineer will serve as a technical leader, mentor, and subject‑matter expert across the organization.
Responsibilities
Develop, validate, and optimize composite manufacturing processes, including layup, curing, bonding, machining, and inspection
Prepare, review, and maintain technical documentation such as drawings, specifications, process instructions, analyses, and test plans
Recommend, evaluate, and qualify composite materials, adhesives, and processes to meet performance, rate, and cost objectives
Support hands‑on fabrication development and provide troubleshooting expertise on the production floor
Lead or participate in design reviews, material trade studies, and failure investigations
Direct complex root‑cause analyses for material and part failures and drive corrective and preventive actions
Provide technical leadership, guidance, and mentorship to junior and mid‑level engineers
Collaborate closely with manufacturing, quality, program management, and design teams to ensure M&P requirements are fully integrated into part and process development
Review and approve composite designs, structural analyses, and manufacturing documentation for technical accuracy and compliance
Interface with raw material suppliers to resolve technical issues and assess new materials that may improve performance or throughput
Minimum Requirements
U.S. Citizenship
Ability to obtain and maintain a U.S. Government security clearance
Ability to pass a negative drug screen and favorable background check
Proficiency with Microsoft Outlook and Office
Travel: 10–15%
B.S. degree and 10+ years of experience in mechanical engineering, aerospace engineering, materials science, or a related discipline; or M.S. degree and 8+ years of experience
10+ years of composites manufacturing experience, including hands‑on shop‑floor involvement
8+ years in the aerospace and defense industry
Deep understanding of composite part fabrication and structural bonding
Familiarity with ASTM and other relevant composite and bonding test standards
Strong technical writing, computer, and presentation skills
Understanding of statistical design allowables
Demonstrated ability to work collaboratively and communicate effectively
Experience with project management
Experience applying structured problem‑solving methodologies for root‑cause and corrective actions
Desired Qualifications
Prior or existing U.S. Government security clearance
Composites design knowledge, including use of statistical allowables
MRB experience
Experience communicating directly with customers
Experience with AS9100 quality management systems
Bonding process expertise
Composites supply chain knowledge
Hands‑on materials test laboratory experience
Familiarity with FAR Part 23, DOT/FAA/AR‑00/47, and CMH‑17G
Physical Demands
Prolonged periods sitting at a desk and working on a computer
Must be able to lift up to 15 pounds at times
Work Environment
Professional office environment with regular work in manufacturing areas
May require occasional use of personal protective equipment
Benefits
Competitive compensation
Health, dental, and vision insurance
401(k) with company match
Paid time off and holidays