Senior Process Manufacturing Engineer

Senior Process Manufacturing Engineer

ZeroAvia

Kemble, United Kingdom

Description

We are seeking a motivated Manufacturing Engineer with a strong background in advanced manufacturing and special processes. This role supports production and engineering teams in developing, validating, and optimising manufacturing methods with a primary focus on machining, metal fabrication, and related special processes.

The successful candidate will also contribute to the development, implementation, and control of special processes whose outputs cannot be fully verified by inspection, such as welding, composites, electronics assembly, and additive manufacturing, ensuring compliance with AS9100, NADCAP, and relevant regulatory bodies.

Key Responsibilities:

• Develop, execute, and maintain CNC machining and fabrication processes, including forming, bending, rolling, and stamping, ensuring compliance with aerospace standards and using CAD/CAM software in compliance with AS9100, NADCAP, and ZeroAvia quality policies.
• Specify tooling, fixtures, and CNC machine setups for prototype and production runs.
• Lead and participate in the qualification, implementation, and monitoring of special processes, ensuring full control plans and process documentation are developed and maintained.
• Support qualification testing and process validation activities with internal quality teams and external regulators.
• Collaborate with Quality and Supply Chain teams to ensure process capability, supplier qualification, and continued compliance.
• Develop and maintain controlled work instructions, process documentation, and inspection plans aligned with aerospace standards.
• Support New Product Introduction (NPI) by translating designs into manufacturable processes, including DFM/DFA analysis.
• Drive root cause analysis, FMEA, and corrective actions for process deviations and non-conformances.
• Apply Lean and continuous improvement methodologies to improve process capability and reduce variation.
• Work cross-functionally with design, production, and quality teams to resolve day-to-day manufacturing challenges.
• Demonstrate a strong safety and quality mindset in all operations.

Requirements

• Degree in Mechanical, Manufacturing, or Production Engineering or equivalent.
• 5+ years’ experience in manufacturing within aviation, aerospace, or a similarly regulated industry.
• Hands-on expertise with CNC machining, tooling, forming, and fabrication processes.
• Experience in qualifying and controlling special processes (welding, additive, composites, electronics).
• Experience working with regulatory authorities (AS9100, NADCAP, CAA/EASA/FAA).
• Strong proficiency in CAD/CAM tools (e.g., SolidWorks, Siemens NX) and familiarity with PLM (Teamcenter), MES, and ERP systems.
• Strong understanding of engineering drawings, GD&T, and aerospace quality standards.
• Practical experience in tooling design, fixture development, and process documentation.
• Familiarity with Lean manufacturing, 5S, and continuous improvement.
• Strong problem solving, collaboration, and communication skills across technical and management teams.