Material & Processes Engineer

PositionThe Materials and Processes Engineer is responsible for the review, evaluation, and approval of aircraft materials, manufacturing processes, and product modifications to ensure compliance with regulatory, airworthiness, quality, and environmental requirements. The role also includes qualification, approval, and surveillance of De Havilland suppliers performing special processes, as well as providing technical leadership and expertise in the selection, application, and control of aerospace materials and manufacturing technologies throughout the product lifecycle.
The incumbent works closely with Design Engineering, Manufacturing Engineering, Supply Chain, Quality Assurance, Regulatory Compliance, external laboratories, and suppliers to ensure materials and processes meet company, customer, and regulatory requirements while supporting safe, reliable, and cost-effective aircraft production and in-service operation.
Responsibilities
Evaluate and approve new metallic and non-metallic materials for aerospace applications, including assessment of mechanical properties, corrosion resistance, durability, manufacturability, and regulatory compliance.
Work closely with material suppliers, special process vendors, testing laboratories, and regulatory authorities in the qualification, validation, and implementation of materials and processes.
Develop, maintain, review, and revise materials specifications, process specifications, engineering standards, and related technical documentation.
Assess materials and processes for compliance with environmental and regulatory requirements, including REACH, EPA, CEPA, RoHS, and other applicable regulations.
Review aircraft repairs, product modifications, concessions, and deviations to ensure compliance with approved materials, manufacturing processes, certification requirements, and airworthiness regulations.
Support root cause investigations and corrective action activities related to material failures, corrosion findings, manufacturing defects, and process non-conformances.
Review, evaluate, and implement new materials technologies, manufacturing methods, and industry best practices to improve product quality, reliability, and competitiveness.
Provide technical guidance and engineering support to internal stakeholders, operators, and maintenance organizations regarding material selection, processing requirements, corrosion prevention, and special process applications.
Plan and conduct supplier audits and assessments to verify compliance with special process requirements, industry standards, and De Havilland specifications.
Evaluate supplier capability, process controls, personnel qualifications, and facility requirements for approval of special process sources.
Review and disposition supplier requests for process deviations, material substitutions, and concessions while ensuring continued compliance with engineering and regulatory requirements.
Collaborate with Quality Assurance, Manufacturing, and Supply Chain organizations to resolve supplier quality issues and drive continuous improvement initiatives.
Support certification, continued airworthiness, and production approval activities related to materials and processes.
Actively participate in continuous improvement initiatives to enhance engineering efficiency, process effectiveness, product quality, and customer satisfaction.
Maintain current knowledge of emerging materials technologies, manufacturing processes, aerospace standards, and regulatory changes affecting the industry.
Support internal and external audits, including quality system, regulatory, customer, and NADCAP audits.
Assist with airworthiness investigations, containment actions, corrective action development, and implementation activities.
Contribute to training, mentoring, and knowledge-sharing activities within the engineering organization.
Support strategic initiatives related to supplier development, process standardization, and technical capability growth.
Perform other duties as assigned.
Qualifications
Bachelor's degree in Materials Engineering, Metallurgical Engineering, Chemical Engineering, Mechanical Engineering, or equivalent discipline.
Licensed Professional Engineer (P.Eng.) or eligible for professional engineering registration.
Minimum of 5 years of relevant aerospace industry experience in materials engineering, metallurgy, manufacturing processes, or special process oversight.
Demonstrated experience with aerospace special processes, including heat treatment, chemical processing, plating, coating, welding, brazing, shot peening, non‑destructive testing, and corrosion prevention/protection systems.
Good understanding of aerospace quality systems and industry standards, including NADCAP, AS9100, and ISO 9001.
Knowledge of Transport Canada, FAA, EASA, and other applicable aerospace regulatory requ