Lead UAS Manufacturing Engineer

COLSA Corporation • Huntsville, AL • 1d ago

General Summary

Assists with the development, stand-up, and optimization of manufacturing operations for a UAS (Unmanned Aircraft Systems) production facility. Responsible for establishing production processes, building and leading an engineering team, and ensuring efficient, scalable manufacturing of aircraft systems and components. Applies broad engineering expertise, including additive manufacturing, machining, digital design tools, and configuration management practices, to support facility design, production readiness, and ongoing operational excellence.

*Principal Duties and Responsibilities (Essential Functions):

Assists with the stand-up and operational readiness of a UAS manufacturing facility, including layout, workflow design, equipment selection, and production line implementation.

Develops, implements, and optimizes manufacturing processes to align with AS9100 for UAS platforms, subassemblies, and components, including additive manufacturing processes such as SLS (Selective Laser Sintering) and FDM (Fused Deposition Modeling).

Establishes and manages additive manufacturing workflows, including part design considerations, build preparation, machine operation, and post-processing for both SLS and FDM technologies.

Determines appropriate use cases for additive manufacturing (proto@type, tooling, end-use parts) and integrates them into production and engineering workflows.

Implements and supports configuration management processes to ensure proper control of product structures, revisions, and engineering changes across manufacturing.

Ensures alignment between engineering designs and production builds through effective use of PDM/PLM systems, maintaining accurate BOMs, revision control, and as-built vs. as-designed traceability.

Supports engineering change management (ECO/ECN), ensuring timely and accurate implementation on the production floor.

Builds, mentors, and leads a manufacturing engineering team to support production, process improvement, and new product introduction (NPI).

Collaborates with design engineering using SolidWorks and PDM systems to ensure manufacturability (DFM/DFA) and proper configuration control of components and assemblies.

Develops and maintains manufacturing documentation including work instructions, process flows, and production routers.

Drives manufacturing readiness activities including process validation, First Article Inspection (FAI), and production ramp-up.

Identifies, analyzes, and resolves complex manufacturing and production issues using data-driven methods and engineering best practices.

Implements lean manufacturing principles, continuous improvement initiatives, and cost reduction strategies.

Oversees selection, installation, and qualification of manufacturing equipment, tooling, and test systems, including additive manufacturing equipment.

Develops and maintains production metrics, KPIs, and reporting systems to track performance, throughput, and quality.

Partners with supply chain and logistics teams to ensure material availability, kitting strategies, and production flow alignment.

Ensures compliance with safety, quality, and regulatory requirements applicable to aerospace/UAS manufacturing.

Provides technical leadership and guidance to junior engineers and production staff.

At COLSA, people are our most valuable resource and centered at our core value. We invite you to unite your talents with opportunity and be a part of our "Family of Professionals!" Learn about our employee-centric culture and benefits here (http://www.colsa.com/culture_benefits/) .

Required SkillsRequired Experience

Job Specifications:

Bachelor's degree in Engineering (Mechanical, Aerospace, Manufacturing, or related discipline) or equivalent experience

10-15+ years of experience in manufacturing engineering, preferably in aerospace, defense, or advanced manufacturing environments

Demonstrated experience standing up or scaling a manufacturing facility and engineering team

Hands-on experience with additive manufacturing, including SLS (Selective Laser Sintering) and FDM (Fused Deposition Modeling)

Strong proficiency in SolidWorks and experience with PDM/PLM systems for design control and configuration management

Experience with configuration management practices, including BOM control, revision management, and engineering change processes (ECO/ECN)

Strong knowledge of production process development, tooling, and manufacturing systems

Experience with UAS, aerospace structures, avionics integration, or electromechanical assemblies preferred

Familiarity with lean manufacturing, Six Sigma, and continuous improvement methodologies

Experience with ERP/MRP systems and production planning tools

Knowledge of quality and regulatory standards (e.g., AS9100D, ISO 9001) preferred

Strong leadership, project management, and problem-solving skills

Ability to obtain and maintain an Interim Secret clearance within 6 months of hire; US Citizenship required

Preferred Qualifications

Experience with UAS, aerospace structures, avionics integration, or electromechanical assemblies

Familiarity with configuration management practices, including BOM control, revision management, and ECO/ECN processes

Knowledge of quality and regulatory standards, such as AS9100 and ISO 9001

Experience with First Article Inspection (FAI), process validation, and production readiness activities

Experience with documentation development, work instructions, and process flows

Knowledge of kitting, line-side delivery, and material flow optimization in production operations

Experience establishing additive manufacturing workflows, including design considerations, build preparation, machine operation, and post-processing for SLS and FDM parts

Applicant selected will be subject to a government security investigation and must meet eligibility requirements for access to classified information. COLSA Corporation is an Equal Opportunity Employer, Minorities/Females/Veterans/Disabled. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, or national origin.

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