The Master Composite Technician (Level 3- Level 4) is a senior-level expert responsible for producing tight-tolerance, high-performance composite structures for aerospace, space systems, defense, missile systems, UAV platforms, or advanced industrial applications. This role requires mastery in pre-preg lamination, filament winding, structural bonding, vacuum processing, and autoclave curing. Level 3-4 technicians function as the primary technical authority on the production floor, resolving complex issues, mentoring technicians, and ensuring aerospace-grade quality and repeatability.
Responsibilities:
Perform advanced composite lay-ups for structural components such as spars, tubes, pressure vessels, control-surface structures, bonded assemblies, and launch-vehicle hardware. Execute high-complexity fabrication processes including pre-preg lamination, filament winding operation and setup, vacuum bagging, vacuum infusion, VARTM, and structural adhesive bonding. Manage autoclave and oven cure cycles, ensuring proper material handling, out-time tracking, tack management, vacuum integrity, and adherence to cure profiles. Troubleshoot complex issues such as fiber misalignment, bridging, porosity, resin imbalance, cure variation, voids, delamination, and tooling deviations. Conduct ply verification, in-process checks, dimensional verification, and documentation aligned with AS9100 or equivalent industry standards. Maintain accurate documentation, batch control, serialized traceability, and material tracking from kit to final cure. Mentor Levels 1-3 on advanced composite fabrication techniques, composite tooling preparation, laminate quality, vacuum integrity, and safe operation of equipment. Support engineering with manufacturability feedback related to tooling improvements, ply transitions, winding setups, and composite process parameters. Prepare and maintain composite tooling including mandrels, bond fixtures, molds, cure tools, and winding equipment. Promote safe work practices involving resins, solvents, composite dust, high-temperature operations, pressurized systems, and PPE requirements.
Qualifications:
5-10+ years of advanced composite fabrication experience in aerospace, defense, space, or high-performance structural manufacturing environments. Demonstrated experience producing flight-level or mission-critical composite structures. Strong proficiency in pre-preg lamination, multi-ply construction, tight-tolerance layup, and structural composite fabrication. Advanced knowledge of autoclave curing, vacuum bagging, vacuum-integrity inspection, out-of-autoclave processes, and adhesive bonding. Experience with filament winding setup, mandrel preparation, tension control, and winding-machine operation (strong preference for roles requiring winding). Ability to read and interpret engineering drawings, laminate schedules, ply patterns, and manufacturing documentation. Working knowledge of AS9100 principles including documentation, traceability, and material control. Ability to perform FAI-level inspections, ply checks, and detailed in-process verification. Strong craftsmanship, independent problem-solving ability, and leadership experience mentoring other technicians. High attention to detail, excellent communication, and ability to collaborate with engineering and quality teams. High school diploma required; composite coursework or industry-recognized training preferred.
