Senior Composites Design Engineer

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 role This is one of the first technical hires for iCOMAT US. We are looking for a hands-on senior composites design engineer with significant industry experience, who designs with composites day to day and has done so recently. You will be the design authority on the ground in the US, working closely with our UK engineering team and supervising what is being manufactured as US production ramps up. This is a doing role first: you will own the design work yourself rather than manage a team.

Location and working pattern

• Based in, or within reach of, Dayton, Ohio. Candidates willing to travel regularly to the Dayton area will be considered.

• Hybrid, not remote: at least two days a week on site at our facility, supervising manufacturing and working with the production team.

• This is a long-term position. We are looking for someone who will be based in the Dayton area and grow with iCOMAT US as manufacturing scales.

What will you be doing?

• Develop composite part designs, from concept to detailed design, using CAD tools (CATIA, SolidWorks etc.)

• Work with stress, CAM, software and manufacturing engineers to ensure component structural integrity and manufacturability

• Supervise the manufacture of parts on site, ensuring what is built matches design intent

• Develop a methodology for composite drawings that incorporate plies of varying orientations

• Define CPD models including detailed layups, ply orientations, stacking sequences and transition zones

• Generate, or review and approve, detailed drawings, 3D models and BOMs

• Participate in the development of processes for creating solid geometries from CPD models with varying ply thickness

• Generate and maintain documentation in line with company and industry standards

• Develop design principles for composite components and assemblies

• Support material selection, supplier selection and manufacturing process development

• Lead design reviews and support certification processes

• Aid in the standardisation and automation of design-related processes

• Lead R&T projects from a technical perspective, define project plans and support external customers and project managers with technical updates

• Support and mentor junior engineers as the US team grows

What do we need from you?

• Bachelor's or Master's degree in aerospace, mechanical or another engineering discipline

• At least 10 years of hands-on working experience in a composite design and manufacturing environment

• Recent, hands-on design work: you have personally been designing composite parts in the last few years, not only managing others who do

• Proven composite design experience, preferably in aerospace (automotive also considered)

• Proficiency in 3D CAD software (CATIA preferred)

• Familiarity with design standards and tolerancing

• Strong understanding of composite materials and their manufacturing methods (hand layup, automated deposition etc.)

• Strong analytical, communication and teamwork skills

• Able to be on site in Dayton, Ohio at least two days a week

Nice to have

• Experience designing for tape laying processes (AFP / ATL)

• Experience designing specific aerospace components (e.g. primary or secondary structures)

• Active US security clearance, or eligibility to obtain one

• Team leadership or people management experience (a bonus, not a requirement)

• Familiarity with FEA software

Our Values: Uncompromising Excellence

• Discipline over excuses. We commit. We follow through. We hold ourselves and each other to the highest standard, especially when the pressure is on.

• Push the edge. iCOMAT was built on a refusal to accept that curved fiber could not be manufactured at scale. We innovate where others hesitate.

• Aligned and accountable. Everyone owns their lane, communicates openly, and delivers without being chased. No silos. No ambiguity.

Why iCOMAT?

• 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!