Welding Manufacturing Engineer

Hermeus is a high-speed aircraft manufacturer focused on the rapid design, build, and test of high-Mach and hypersonic aircraft for the national interest. Working directly with the Department of Defense, Hermeus delivers capabilities that will ensure that our nation, and our allies, maintain an asymmetric advantage over any and all potential adversaries.

As a Welding Manufacturing Engineer, you will play a critical role in enabling rapid development, fabrication, and integration of advanced hardware across our R&D and prototype manufacturing environments. You’ll be responsible for developing weld processes, fixtures, and joint designs that bridge early design concepts to flight-ready hardware. This position is hands-on and deeply cross-functional, working directly with design, manufacturing, and test teams to bring complex systems from concept to reality.

• Develop, qualify, and optimize weld processes and parameters for multiple techniques including, but not limited to, electron beam, laser beam, gas tungsten arc, gas metal arc, plasma arc, resistance, friction-stir, and orbital tube welding.
• Support R&D and production builds of welded aircraft structures, tanks, and propulsion assemblies, providing direct guidance to technicians and manufacturing engineers.
• Collaborate with design and manufacturing engineering to drive weld joint design, fixture development, and assembly methods optimized for manufacturability, precision, and repeatability.
• Lead root cause investigations related to weld performance, material compatibility, and process deviations; implement corrective actions based on metallurgical and mechanical findings.
• Plan and execute weld qualification campaigns, including mechanical testing, NDE inspection, and data interpretation.
• Partner with NDE specialists to evaluate weld quality and develop advanced inspection techniques tailored for high-performance aircraft applications.
• Implement process control improvements using feedback from weld tests, NDE, and production data to increase reliability and consistency.
• Identify and integrate automated or robotic welding solutions to improve throughput, consistency, and quality.
• Research and evaluate emerging welding technologies and materials for potential application in hypersonic vehicle manufacturing.
• Collaborate closely with tooling, automation, and integration teams to develop solutions that minimize distortion, improve accuracy, and accelerate production timelines.

• Bachelor’s degree in Mechanical Engineering or other related technical discipline.
• Hands-on fabrication, manufacturing, or testing experience with welded aerospace assemblies.
• Strong understanding of weld design principles and mechanical tolerances under thermal and structural loads.

• Master’s degree in Welding Engineering or related technical field.
• Hands-on welding experience with nickel-based alloys, stainless steel, titanium, copper, and aluminum.
• Experience with brazing, joining, and metallographic interpretation.
• Deep understanding of welding processes including, but not limited to, electron beam, laser beam, plasma arc, resistance, friction-stir, gas tungsten arc, and gas metal arc.
• Robot programming experience for automated welding applications.
• Tooling design experience for welded assemblies to minimize distortion and improve repeatability.
• Knowledge of weld strength testing methodologies, standards, and data acquisition systems (ASTM E8, E399, E740, ISO 15653, AWS D17.X, AWS C7.X, thermocouples, strain gages, etc.).
• Experience performing root cause analysis and corrective actions using techniques such as optical and SEM fractography, hardness testing, chemical analysis, and mechanical testing.
• Demonstrated success applying Design for Manufacturability (DFM) principles to transition welded designs from prototype to production.
• Strong ability to multi-task, prioritize, and communicate results across engineering, manufacturing, and leadership teams.
• Highly detail-oriented with excellent documentation and organizational skills.
• Proven track record of success in fast-paced, high-growth, technically demanding environments.

• Must be willing to work extended hours and weekends as needed to support build schedules and testing operations.
• Occasional travel may be required to support suppliers or test campaigns.
• Ability to perform hands-on work in fabrication and prototype build environments, including climbing, lifting, and working in confined areas as required.
• Desire to be part of a high-intensity, mission-focused team driving innovation in hypersonic aircraft development.

U.S. EXPORT CONTROL COMPLIANCE STATUS 

The person hired will have access to information and items subject to U.S. export controls, and therefore, must either be a “U.S. person” as defined by 22 C.F.R. § 120.62 or otherwise eligible for deemed export licensing. US persons include U.S. citizens, U.S. nationals, lawful permanent residents (green card holders), and asylees and refugees with such status granted, not pending. 

EQUAL OPPORTUNITY

Hermeus is an Equal Opportunity Employer. Employment decisions at Hermeus are based solely on merit, competence, and qualifications, without regard to race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability, or any other legally protected status.