Principal R&D Engineer (Material Test Team Leader)

Salary from; £49,047

Spirit AeroSystems designs and builds aerostructures for both commercial and defense customers. With headquarters in Wichita, Kansas, Spirit operates sites in the U.S., U.K., France, and Malaysia. The companys core products include fuselages, pylons, nacelles, and wing components for the worlds premier aircraft. Spirit AeroSystems focuses on affordable, innovative composite and aluminum manufacturing solutions to support customers around the globe.

The Opportunity

Spirit AeroSystems – where flight begins.

Spirit AeroSystems is actively developing technologies that will enable zero carbon emission flight. As our research in this field expands, we are growing the Prestwick team based at our state-of-the-art research and technology development facility, the Aerospace Innovation Centre (AIC). The AIC showcases Spirit’s distinctive capabilities as a global centre for design and digital manufacturing of current and future aircraft. Partnering with Universities, industry leaders, and the UK’s CATAPULT network the AIC is a focal point to collaborate, innovate, train and develop skills for today and tomorrow. Spirit is developing structures and systems technologies to enable our industries transition to net zero emissions.

This exciting opportunity requires candidates to work in an agile, diverse and fast paced environment developing cutting edge technologies for aerostructures and future fuels integration. The successful candidate will deliver expert R&T test leadership and integrate across our analysis, R&D, systems, and test teams in a rapid design, build and test environment. R&D areas of focus include metallics, composites, future fuels storage and integration, digital factory & harnessing new developments in IT. Diversity and inclusion are key to innovation. We are committed to fostering a culture where all employees can share their passions and ideas so we can tackle the toughest challenges in the industry.

Role Purpose

To develop and execute R&D projects/work packages from proposal scope and budget submission to final technical project delivery by leading a team of engineers and technicians to complete projects to high quality, ensuring schedule adherence and within allocated budget. To liaise with partners, technology providers and customers in the detailed development and collaboration of composite R&D programmes, providing detailed reports and presentations on activities undertaken and scope of work definition. To develop and deliver new innovative R&D projects related to composite & metallic materials and processes, design, stress analysis methods and tools, quality and inspection methodologies as well as automation technologies integrating them into primary structural solutions for future aerostructures component and assembly products. Ensuring technology portfolio integration in line with product development timescales, technology and business strategy. Ensuring compliance of Spirit Proprietary technologies against Manufacturing Readiness Level (MRL) and/or Technology Readiness Level (TRL) methodologies.

This opportunity, based at our Prestwick campus, offers:

• 37 hour working week (half day Friday).
• 33 days holiday per year, rising with service.
• Annual Bonus related to company performance.
• Defined contribution pension scheme (default contributions; 4 employee and 8 employer).
• Virtual GP Service 365 days per year.
• Employee Assistance Program.
• A wide range of flexible benefits.
• Death in service payment (default 4 times basic salary).
• Cycle To Work Scheme.
• Professional development and growth.
• A collaborative, dynamic working environment.

• Developing and leading R&D projects/work packages from proposal scope and budget submission to final project delivery in line with the agreed schedule, ensuring on time deliverables are achieved within the allocated budget and to high quality.
• Leading a team of engineers and/or technicians to complete projects to high quality, ensuring schedule adherence.
• Liaising with partners, technology providers and customers in the detailed development and collaboration of composite R&D programmes, providing detail reports and presentations on activities undertaken and scope of work definition.
• Researching composite material related technologies and determining their potential application on the design, fabrication, verification and assembly of various structural components.
• Developing bespoke fabrication, verification and assembly equipment and techniques to provide cutting edge solutions to future wing aerostructures products.
• Adopting design of experiments and appropriate analytical methodologies to optimise material performance and fabrication process robustness (DSE, DMA, microscopic investigation, Darcy laws, permeability measurement)
• Developing and compiling test programmes for sub-element testing of features of the structure’s design that will lead to the certification of the composite component.
• Prepare reports on project results, composite material requirements document and the subsequent test evaluation of the materials based on either customer and/or Spirit proprietary processes.
• Liaising with equipment suppliers in the development of computer controlled visual detection inspection tools enabling quality assessment without the need for human interference through a thorough understanding of the composite fabrication process and their quality.
• Designing metrology inspection techniques that will identify and verify composite component fabrication compliance.
• Ensuring technical solution integration in line with product development timescales, technology and business strategy.
• Ensuring compliance of Spirit Proprietary technologies against Manufacturing Readiness Level (MRL) and/or Technology Readiness Level (TRL) approaches.

Knowledge, Skills and Experience

• Strong knowledge in composite & metallic technologies and the testing thereof, ideally in a research and development environment
• In depth understanding of typical composite polymers and metallics material test equipment coupled with physical, chemical and mechanical test methods (DSE, DMA, Microscopic investigation, NDI)
• Applied know-how in one or more of the following composite related disciplines: composite design, analysis, material and fabrication, testing, assembly and quality inspection processes.
• Solid understanding of composites and metallics mechanical and physical behaviors
• Relevant experience in planning, developing and leading R&D projects/packages of work and/or small tasks to agreed time, quality and costs
• Relevant experience in developing R&D projects proposals/projects from proposal scope and budget definition to final technical project delivery to time, cost and quality
• Relevant experience in leading a team of engineers and/or technicians to complete project technical scope and schedule adherence
• Relevant background in complex technology integration R&D projects
• Excellent interpersonal, influencing skills and a team working “ethos”
• Excellent report writing and presentation skills
• Excellent problem solving and analytical skills are essential for this role
• Excellent organisational and planning skills
• Self driven, professional approach with a “can do” attitude to innovation
• A good grasp of Microsoft packages such as Word, Excel & Outlook is required
• Desirable – MSc in Aerospace/Mechanical Engineering, material polymer science/or equivalent relevant degree/experience

Decision Making Authority

• The jobholder shall plan, cost and schedule the project with little input from the manager with extensive authority to take it to completion.
• The jobholder shall have the authority for the decision making process surrounding the business case and will have the responsibility to justify it to R&T management.
• The jobholder may order equipment, tooling etc to complete the project within the bounds of the agreed budget.
• The jobholder would receive technical direction from the R&D Manager prior to making final project decisions. It is anticipated however that the jobholder would have a completed a project technical plan that encompasses all the relevant information for the final decision to be given.
• The jobholder would be expected to take authority in ensuring that the relevant inputs to the project are maintained and realised.

We are looking for people who want to make a difference, talented team members with the skills and passion to become the best at what they do.

Closing Date; Monday, 9th June at 12pm

Spirit AeroSystems is an equal opportunity employer and considers qualified applicants for employment without regard to race, colour, creed, religion, national origin, sex, sexual orientation, gender identity and expression, marital or civil partnership status, pregnancy, age, disability, veteran status or any other protected factor under federal, state or local law.