Develop and optimize composite manufacturing processes, tooling, and documentation to transition designs to flight-ready hardware. Support prototyping, low-rate production, troubleshooting, process improvements, and ensure quality compliance for aerospace composite structures.
About Opterus
Opterus Research and Development is an aerospace company specializing in advanced deployable space structures and subsystems. We combine cutting-edge composite materials, origami-inspired architectures, and elegant engineering to deliver lightweight, high-performance solutions for commercial, defense, and scientific missions.
Position Overview
Opterus is seeking a Composites Engineer (level II or III) to support the development and production of advanced composite components and structures. This role bridges engineering and manufacturing, focusing on analysis-driven design, process development, manufacturing tooling development, manufacturability, quality, and continuous improvement across composite fabrication, assembly, and inspection. You’ll work closely with design engineers, technicians, and program teams to transition innovative composite designs from concept to repeatable, flight-ready hardware.
Key Responsibilities
- Develop, document, and optimize composite manufacturing processes (layup, curing, bonding, trimming, and assembly)
- Provide input on composite laminates based on structural performance requirements
- Develop mechanical tooling and GSE system design and fabrication for composite structure manufacturing and test
- Mold tooling, layup tooling, precision trimming and machining systems, part transfer/handling, verification tooling, etc.
- Interpret engineering requirements and drive manufacturable designs, work instructions, travelers, and process specifications
- Support prototype builds, first-article manufacturing, and low-rate production
- Collaborate with structural engineers to improve composite material system performance, manufacturability, yield, and cost
- Provide hands-on support on the production floor during builds and troubleshooting
- Provide material choice inputs for composite layup consumables such as mold release, release films, peel plies, bagging, etc.
- Identify and implement process improvements to enhance quality, efficiency, and repeatability
- Assist with root cause analysis and corrective actions for nonconformances
- Ensure compliance with internal quality systems and applicable aerospace standards
Required Qualifications
- Bachelor’s degree in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or a related field
- 4+ years of experience in composite manufacturing or aerospace manufacturing engineering in a production environment.
- Working knowledge of composite materials and processes (prepreg, wet layup, autoclave/oven cure, bonding)
- Working knowledge of composites theory (constituent materials, anisotropy, micromechanics, micromechanics)
- Experience with CAD design tools (SolidWorks preferred) and mechanical design
- Experience developing manufacturing documentation and process controls
- Ability to work cross-functionally in a fast-paced, development-driven environment
- Strong problem-solving and communication skills
Preferred Qualifications
- Experience with aerospace or space-flight hardware
- Familiarity with high strain composites
- Experience supporting prototype and low-volume production programs
- Understanding of quality systems, first article inspection (FAI), and nonconformance processes
Compensation and Benefits
- Base salary range of $90,000-128,000 based on experience and qualifications
- Flexible and hybrid work schedules (two or more days in office per week)
- Comprehensive benefits package including Medical, Dental, Vision, Short-Term Disability, Long-Term Disability, Life, and AD&D insurance
- Opterus pays 100% of employees’ premiums and 70% of dependents’ premiums
- 401K matching up to 4%
- 9 paid holidays
Opterus Research and Development Loveland, Colorado, USA Office
Loveland, CO, United States
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