Composite Senior Technician, Prototype (R4609)

Responsibilities

Wire Harness / PCBA Assembly, Inspection and Testing

• Read and interpret aerospace schematics, technical drawings, and detailed work instructions.
• Measure, cut, strip, crimp, and terminate wires and cables to precise tolerances using specialized tools and equipment.
• Assemble wire harnesses, connectors, backshells, and shielding components per aerospace industry standards.
• Route wires carefully to meet form board layouts, bend radii, and environmental specifications.
• Perform board hardening and gel coating procedures.
• Coordinate with Avionics team members for the successful testing and provisioning of software on to Boards.

Mechanical Assembly / Composite Airframe

• Conduct engine assembly, disassembly, and integration for UAV propulsion systems.
• Perform composite assembly work including basic layup procedures, bonding, vacuum bagging, running cure cycles, etc.
• Diagnose and resolve mechanical, electrical, and performance issues.
• Work closely with engineers and flight test teams to ensure system readiness.

Quality and Compliance

• Perform visual inspections, continuity testing, and high-voltage insulation resistance testing to verify conformance to aerospace standards.
• Ensure all work adheres to IPC/WHMA-A-620 Class 3, AS9100, and other aerospace quality requirements.
• Identify and repair defects, ensuring zero tolerance for errors that could impact safety or reliability.
• Maintain traceability of all components, wires, and work performed.

Documentation and Reporting

• Accurately complete production records, test logs, and quality assurance reports.
• Maintain detailed documentation for traceability and compliance with aerospace industry standards.

Collaboration and Continuous Improvement

• Work closely with engineers, quality control, and production teams to troubleshoot and resolve technical issues.
• Provide feedback for process improvements and ensure compliance with lean manufacturing principles.

Adherence to Safety Protocols

• Follow all safety regulations, including ESD (Electrostatic Discharge) prevention, PPE requirements, and cleanroom protocols where applicable.
• Maintain a clean and organized workspace in line with aerospace safety standards.

Required Qualifications

Technical Skills

• Strong proficiency in reading and interpreting aerospace schematics, blueprints, and work instructions.
• Experience in wire harness assembly, including crimping, soldering, and connector assembly.
• Experience handling and working with PCBAs.
• Composite assembly skills including basic layup procedures, bonding, vacuum bagging, running cure cycles, etc.
• Engine assembly, disassembly, and integration.
• Familiarity with aerospace-specific components such as MIL-SPEC connectors, backshells, braiding, and shielding.
• Experience with quality standards like IPC/WHMA-A-620 Class 3, AS9100, and MIL-STD requirements.

Attention to Detail and Precision

• Ability to work with tight tolerances and ensure 100% quality in all wire harness assemblies.
• Strong problem-solving skills for identifying and addressing manufacturing defects.

Certifications

• IPC/WHMA-A-620 Certification required or willingness to obtain.
• Certification in soldering to J-STD-001 standards preferred.

Physical Requirements

• Ability to work with small components, perform repetitive tasks, and sit or stand for extended periods.
• Good manual dexterity and hand-eye coordination.