Composites Manufacturing Engineer

Swarm Aero is redefining air power by building the largest swarming UAV and the most versatile swarming aircraft network in the world. We are rapidly moving towards launching the first aircraft specifically designed for swarming, along with the Command & Control software to mobilize swarms of thousands of heterogeneous autonomous assets, empowering human operators to achieve superhuman results.

Our team has successfully created and exited multiple startups, negotiated defense deals worth billions of dollars, and designed and built over 30 novel aircraft. We bring aerospace experience from top entities, including Scaled Composites, SpaceX, Airbus, Archer Aviation, Blue Origin, and Boom Supersonic.

Swarm Aero is looking for a highly motivated and experienced Composites Manufacturing Engineer to join our dedicated team. The ideal candidate will be responsible for leading all composite fabrication efforts from tooling and layup through cure and finishing as we scale production of advanced autonomous aircraft.

What You'll Do

• Partner directly with design engineers to develop composite aircraft structures for production and drive Design for Manufacturability (DFM) improvements specific to composite materials and processes.
• Design, fabricate, and qualify composite tooling including molds, mandrels, cauls, and fixtures using materials such as carbon fiber, fiberglass, Invar, and aluminum.
• Develop and implement composite manufacturing processes including wet layup, prepreg layup, resin infusion (VARTM), autoclave and out-of-autoclave (OOA) cure cycles, filament winding, and pultrusion.
• Establish and maintain composite process documentation including layup instructions, cure cycle specifications, material traceability records, and non-conformance procedures.
• Conduct material and process qualifications, including coupon testing programs and first-article inspections for new composite parts and assemblies.
• Lead non-destructive inspection (NDI) activities such as ultrasonic testing, tap testing, and digital radiography to ensure structural integrity of composite components.
• Own the production of composite prototype structures and support the transition to full-rate manufacturing, including training technicians and building out composite shop capabilities.
• Collaborate cross-functionally with structures, manufacturing, and quality teams to resolve in-process defects and drive continuous improvement.

What You've Done

• Bachelor's degree in Aerospace Engineering, Materials Science, Mechanical Engineering, or related field. An advanced degree is preferred.
• 5+ years of hands-on experience in composites manufacturing, preferably in aerospace or defense.
• Deep expertise in composite fabrication processes including prepreg, infusion, wet layup, autoclave, and OOA methods — with direct hands-on experience, not just oversight.
• Experience designing and building composite tooling (molds, mandrels, cauls) and understanding of thermal expansion considerations for tool materials.
• Proficiency with composites-related software and CAD tools such as Fibersim, Siemens NX, CATIA, or similar for ply book generation and flat pattern development.
• Familiarity with material specifications (e.g., BMS, Cytec, Toray), material qualification standards, and traceability requirements.
• Working knowledge of NDI methods and composite repair procedures per industry standards (e.g., SAE, ASTM, MIL-HDBK-17 / CMH-17).
• Solid understanding of quality control principles and composite inspection practices in a production environment.

What Sets You Apart

• You like to build and break things. You're equally comfortable on the shop floor with tools in hand as you are writing process specs.
• You ask for forgiveness instead of permission and thrive in a fast-moving, resource-constrained startup environment.
• Proven track record of taking composite structures from concept to flight hardware on aggressive schedules.
• Experience standing up composite shop capabilities from scratch, including equipment procurement, process development, and technician training.
• Strong understanding of the structural mechanics behind the composites you build. You know why the laminate schedule matters.
• Excellent problem-solving skills with a bias for action when defects or process escapes arise.
• Ability to juggle multiple programs and priorities without losing attention to detail on process compliance and quality.

What we Offer: 

• Meaningful equity stake in a high-growth defense technology company 

• Competitive base salary commensurate with experience  

• Comprehensive benefits including medical, dental, vision, and 401k 

• PTO and Paid Sick Time 

• Monthly Wellness Stipend 

• Daily catered lunch to office 

• Paid Parental leave  

• Flexible work arrangement - remote/hybrid with regular collaboration in Oxnard 

• Direct impact opportunity - be a key leader in building a critical technology for national security 

• World-class team - work alongside exceptional engineers and operators solving hard problems 

Compensation Range:

• $140,000-190,000 + Equity

As part of our commitment to maintaining a safe and trustworthy work environment, Swarm Aero conducts a thorough screening of prospective employees. Candidates will be subject to a comprehensive background verification process as a prerequisite for employment.  

ITAR Requirements: To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.