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Lead Prototype Tech Aviation Consulting Experts, Inc. • Frisco, Texas •

PERMANENT

Updated 08/2026 Job Description Job Summary Position Summary The Lead Prototype Technician will serve as a hands-on technical leader within Prototype Manufacturing, transforming engineering concepts into flight-ready aircraft hardware. This role works directly with Design Engineering, Manufacturing Engineering, Quality, and Production to execute developmental, and first-article builds while establishing repeatable processes for future production. This is a highly hands-on position, with more than 50 of the work performed directly on aircraft hardware. The technician will also provide technical leadership, mentor other technicians, troubleshoot complex manufacturing issues, and help transition prototype designs into scalable production processes. Key Responsibilities Prototype Aircraft Manufacturing Build prototype, developmental, and first-article aircraft from engineering concept through flight-ready hardware. Perform precision drilling, reaming, countersinking, riveting, fastening, torquing, safety wiring, structural assembly, and mechanical integration. Execute advanced composite work, including wet layup, bonding, trimming, machining, vacuum bagging, structural repair, finishing, and final assembly. Perform complex aircraft modifications, structural repairs, and prototype rework. Fabricate custom brackets, tooling, fixtures, and developmental hardware. Support engineering validation, qualification builds, ground testing, and flight-test campaigns. Technical and Engineering Support Interpret complex engineering drawings, CAD models, GD&T, specifications, system diagrams, and manufacturing documentation. Partner directly with Design Engineering to resolve build issues and provide Design for Manufacturability feedback. Troubleshoot complex structural, mechanical, composite, and cross-disciplinary manufacturing problems. Identify design or process risks before they become production issues. Provide practical manufacturing recommendations for nonconformances during prototype and early-production builds. Track open technical issues, build risks, configuration changes, and lessons learned. Process Development and Prototype-to-Production Transition Develop and improve manufacturing work instructions, build sequences, tooling concepts, fixtures, and standardized assembly methods. Establish prototype build standards, craftsmanship requirements, and handoff criteria. Maintain prototype tooling readiness, laboratory standards, and configuration control. Create and maintain transition packages for transferring prototype hardware and processes into production. Capture build knowledge and convert prototype learning into repeatable manufacturing processes. Lead continuous-improvement initiatives focused on manufacturability, build quality, efficiency, and learning velocity. Technical Leadership Lead daily prototype build execution, work sequencing, and resource coordination. Coordinate with Engineering, Manufacturing Engineering, Quality, and Production regarding priorities, schedules, design maturity, and build readiness. Mentor and provide technical direction to Prototype Technicians. Develop training materials, process guidelines, and technical standards. Support technician qualification and certification activities. Maintain training and skill matrices for the prototype team. Promote high standards for safety, quality, accountability, and aircraft craftsmanship. Required Qualifications 10 or more years of aerospace manufacturing, aircraft assembly, prototype, NPI, or engineering-development build experience. Extensive hands-on aircraft structural assembly experience. Advanced experience with precision drilling, reaming, countersinking, riveting, fastening, torqueing, safety wiring, and mechanical integration. Experience performing complex aircraft modifications and structural repairs. Advanced composite-manufacturing experience, including wet layup, bonding, vacuum bagging, trimming, machining, and structural repair. Demonstrated experience supporting prototype, developmental, or first-article aircraft builds. Ability to interpret complex engineering drawings, CAD models, GD&T, specifications, and manufacturing documentation. Strong troubleshooting, root-cause analysis, and problem-solving abilities. Demonstrated technical leadership, coaching, or mentorship experience. Strong written and verbal communication skills with the ability to work effectively across Engineering, Quality, and Manufacturing organizations. Ability to perform more than 50 hands-on direct aircraft work. Ability to obtain and maintain a U.S. Security Clearance. Preferred Qualifications Experience with military aircraft, unmanned aerial vehicles, eVTOL aircraft, rotorcraft, or other advanced aerospace platforms. Prototype-to-production or NPI transition experience. Experience developing manufacturing work instructions, build standards, tooling concepts, and standardized processes. AS9100 manufacturing experience. Lean Manufacturing or Six Sigma experience. A&P License, IPC certification, or other applicable technical certification. Military aviation maintenance experience. Experience reading system-level, wiring, or circuit diagrams, as applicable. Previous experience leading or coordinating prototype build activities. Measures of Success Deliver complex prototype aircraft hardware safely, accurately, and on schedule. Maintain exceptional workmanship and quality standards. Resolve manufacturing challenges before they affect production. Provide actionable DFM feedback to Engineering. Establish repeatable and scalable manufacturing processes. Improve tooling, documentation, work sequencing, and build execution. Successfully capture and transfer prototype knowledge into production. Mentor technicians and strengthen the overall technical capability of the team. Why ACES Time and a half overtime pay Full max per diem benefits Benefits Paycheck Advances Longevity Bonus Life Insurance Referral Bonus Program 401K 6 Paid Holidays Job and company information not to be copied, shared, scraped, or otherwise disseminated without explicit consent of JSfirm, LLC.