Join ICOMAT – Revolutionising the Future of Lightweight Manufacturing!

iCOMAT is an advanced manufacturing company that invented Rapid Tow Shearing (RTS) - the only proven technology for producing defect-free curved-fiber composite parts at industrial scale. We deliver the lightest structures possible for aerospace, automotive, defense, and space, at a rate and cost efficiency that far exceeds existing composite production processes.

We build and operate automated factories for composite materials, delivering components to Tier 1 suppliers and OEMs. The business has three main divisions: development of automated production machines, development of software design and production tools, and operation of the factory. We work with 25+ customers and completed the largest ever Series A in composites manufacturing to fuel a significant scale-up, with growth plans that will see the business multiply in size over the next two to three years and expand operations into the UK, Europe and the US.

The business has currently more than 130,000 sqm of production capacity with manufacturing facilities in the UK (Gloucester and Swindon) and the US (Dayton, Ohio); a Hardware R&D Centre in Bristol, UK; and a Software R&D Centre in Athens, Greece.

The primary role of a Metallics ME (Process Engineer) is to take build-to-print components, tooling or parts from Design Engineering and customer definition through industrialisation and into stable production, ensuring that the risks and processes required to manufacture the items have been evaluated (typically TRL6 to TRL9). The role provides clear manufacturing instructions and process control to ensure design intent, quality compliance and customer requirements are met. The role is centred equally around New Product Introduction (NPI) and Continuous Improvement (CI), supporting both the controlled introduction of new metallic products and the improvement of existing production processes

What will you be doing? 

• Support Business Development and Contract Review with manufacturing methodology, costings, NRE requirements, cycle-time estimates and capacity assumptions.

• Review customer drawings, CAD models, specifications, purchase-order requirements and technical data to establish the complete manufacturing scope.

• Support product design for manufacture and complete Design for Manufacture reviews as required.

• Develop the manufacturing strategy for new metallic components, including machining methods, operation sequence, workholding, tooling, datum strategy and inspection approach.

• Identify and define external and special-process requirements, including anodising, passivation, plating or coating, heat treatment, crack detection/NDT, part marking and finishing.

• Create and maintain manufacturing Routings and BoMs.

• Create full Methods of Manufacture, providing:

• Step-by-step manufacturing instructions.

• Health & Safety requirements, including COSHH assessments where required.

• Tooling, jig, fixture and workholding requirements.

• Equipment, CNC machine and inspection-equipment requirements.

• Key material specifications, raw-material form, size and manufacturing allowances.

• Machining parameters, CNC program references and controlled setup requirements where applicable.

• Special-process, finishing, part-marking, handling, protection, storage, packaging and transport requirements.

• Ensure all customer specifications, quality approvals and compliance requirements have been identified and incorporated into the manufacturing process.

• Develop Process Sheets and Standard Operating Procedures as required.

• Work with Quality to develop and implement quality-control procedures, Control Plans and inspection plans, including first-off, in-process and final inspection requirements.

• Define CMM, gauge and metrology requirements and support Gauge R&R activity where appropriate.

• Work with Tooling Design, Operations and suppliers to create tooling concepts and requirements.

• Develop PFMEAs to identify and mitigate manufacturing risks and ensure resulting controls are transferred into production documentation.

• Lead or support gated NPI and manufacturing-readiness reviews, confirming that routings, tooling, resources, cycle times, inspection methods and special processes are ready before release to production.

• Support FAIR and Delta FAIR activity and ensure the required manufacturing evidence is available for product approval.

• Provide hands-on Manufacturing Engineering support to live metallic production and resolve machining, dimensional, surface-finish, handling, marking and process issues.

• Use structured problem-solving methods, including 5 Why, 8D and A3, to identify root causes and implement sustainable corrective actions.

• Review production data, scrap, rework, concessions, inspection failures and recurring defects and recommend improvements in quality, cost, delivery, capacity and process reliability.

• Lead Continuous Improvement activity to optimise CNC processes, tooling, fixtures, workholding, operation sequencing, standard work and cycle time.

• Develop mistake-proofing and process controls that reduce variation and reliance on operator judgement.

• Maintain accurate manufacturing data within ERP/MRP systems, ensuring BoMs, routings, cycle times and work instructions reflect the approved production process.

• Support Procurement and Supply Chain with technical guidance, supplier selection, special-process requirements and resolution of supplier-related manufacturing issues.

Skill Set / Experience / Qualifications

• Practical knowledge of metallic component manufacture within a precision engineering environment essential.

• Strong understanding of CNC machining processes, preferably both milling and turning.

• Understanding of cutting tools, feeds and speeds, workholding, fixtures, datums, tolerances and surface-finish requirements.

• Ability to interpret complex engineering drawings, GD&T, customer specifications and technical work packages.

• Experience of NPI and industrialisation of machined metallic components.

• Experience creating manufacturing Routings, BoMs, Methods of Manufacture and controlled work instructions.

• Understanding of AS9100 and quality control within an aerospace or similarly regulated environment.

• Knowledge of FAIR and gated manufacturing-readiness processes advantageous.

• Understanding of PFMEA, Control Plans, inspection planning, CMM inspection and gauge selection.

• Knowledge of metallic materials and aerospace alloys, including aluminium, stainless steel and titanium, advantageous.

• Knowledge of special processes such as anodising, passivation, chemical conversion or coating, plating, heat treatment, NDT/crack detection and part marking advantageous.

• Proficiency in CAD (SolidWorks and Composer), Word and Excel.

• CNC programming or CAM experience advantageous but not essential.

• Analytical thinking, structured problem-solving and creativity.

• Knowledge and practical application of Lean Manufacturing and Continuous Improvement methods.

• Communication and teamwork skills for cross-functional collaboration with Operations, Quality, Supply Chain, Planning, Design Engineering and external suppliers.

• Ideal but not essential, degree or HNC/HND qualification in Manufacturing, Mechanical or Production Engineering; strong relevant manufacturing experience will also be considered.

• Six Sigma Green/Black Belt advantageous but not essential.

Our Values: Uncompromising Excellence

• Competitive Salary & Benefits: We offer a comprehensive benefits package, including private healthcare, pension scheme.

• Stock Options: Equity options to give employees a stake in the company’s success

• Career Growth Opportunities: Join us at a pivotal time as we scale up, offering unmatched professional growth opportunities in the rapidly advancing field of composite materials.

• Innovation-Focused Culture: We pride ourselves on our inclusive, forward-thinking work environment. Recognized by Bloomberg as a "UK Startup to Watch," iCOMAT celebrates diversity and encourages all applicants, regardless of background, to apply.

• Global Impact: Be a part of our mission to redefine lightweight structures for the automotive, aerospace, and space industries, working with some of the most influential companies worldwide.Ready to be part of something big? 

Apply now to learn more and join us on our exciting journey!