Head of Composite Manufacturing Engineering
Gloucester Point, VA, USA
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.
As Head of Composite Manufacturing Engineering you will own how iCOMAT makes composite parts, across every plant. You will set the process standards, technical governance and long-term manufacturing engineering strategy that our plant Manufacturing Engineering Leads deliver locally, taking Rapid Tow Shearing (RTS) from a proven technology to a repeatable, rate-capable production system at multiple sites. The role is based at Factory 1 in Gloucester, reports to the Director of Engineering, works closely with the Director of Global Manufacturing Operations, and includes regular travel to our UK facilities.
What will you be doing?
Ways of Working & Standards
Setting the day-to-day tempo and way of working for the Manufacturing Engineering team. You will own the process standards, specifications, routings, Methods of Manufacture and ME practices used on the shop floor, so that every part is built the same way, every time, at every site.
Leadership & Team
Leading the plant Manufacturing Engineering Leads and, through them, the Manufacturing Engineering and Tooling teams at each site. You will set objectives, build capability and succession, and grow the function as we open new factories. This is a hands-on role: you will get stuck into the hardest technical problems yourself.
Process Development & Industrialisation
Owning industrialisation of new parts and processes from order to production release through APQP, PFMEA, control plans, FAIR and production readiness reviews. You will work with the RTS machine, software and design teams to turn development processes into robust, documented production processes covering layup, cure, trim, machining, bonding and NDT.
Quoting & Cost Estimation
Owning the manufacturing engineering input to every quote. You will work with Business Development to define the manufacturing methodology, estimate cycle times, labour, materials, tooling and cost per part for new programmes, and make sure what we quote is what we can build, at the rate and margin we committed to.
Rate, Cost & Capacity
Driving cycle time, yield, scrap and cost per part in the right direction with lean and structured problem-solving. You will provide the manufacturing engineering input to business cases, capacity plans and new factory layouts, and support Business Development with manufacturing methodology, cost estimates and quotations for new programmes.
Quality & Customer Interface
Partnering with the Head of Quality to build quality into the process rather than inspect it in, through AS9100-aligned documentation, root cause analysis and effective corrective action. You will represent Manufacturing Engineering in technical reviews and audits with customers and OEMs.
What do we need from you?
• Composite manufacturing engineering is the number one requirement: 10+ years in aerospace, defence or space production, including taking parts from development into rate production
• 5+ years leading manufacturing engineering teams, ideally including leads or managers, and ideally across more than one site
• Deep, hands-on knowledge of composite processes: prepreg layup, autoclave and out-of-autoclave cure, trimming and machining, bonding and NDT, and how materials behave throughout
• Strong command of industrialisation tools (APQP, PFMEA, control plans, FAIR, production readiness reviews)
• Working knowledge of AS9100 and aerospace quality requirements
• Proven record of improving yield, cycle time and cost using lean and structured problem-solving (8D, 5 Whys, Fishbone)
• Solid understanding of composite tooling design, materials and qualification
• Degree in Manufacturing, Mechanical, Aerospace or Materials Engineering, or equivalent working experience
• Clear communicator who can set direction for engineers and hold their own with customers, operations and the executive team
• Proactive and resilient mindset, comfortable building structure in a fast-moving scale-up
Nice to have
• Experience with automated composite processes such as AFP or ATL
• Experience standing up a new factory, production line or greenfield site
• Exposure to US aerospace and defence manufacturing, including ITAR environments
• Nadcap experience and OEM customer-specific requirements
• Six Sigma Black Belt or Chartered Engineer status
Working conditions
• Manufacturing and office environment, based at Factory 1 in Gloucester
• Regular travel to Swindon and abroad plus occasional travel to customers and suppliers
• Flexibility to work extended hours when production or programme launches need it
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!