Manager Test Engineering & Metrology

Test Engineering & Metrology Manager

Energetic Components New Product Development Aerospace & Defense

Position Summary

The Test Engineering & Metrology Manager is a hands-on technical leader responsible for building leading and maturing the test engineering and metrology function that supports new product development (NPD) of energetic componentsincluding initiators igniters propellants pyrotechnic actuators and related energetic subassembliesfor aerospace and defense customers. This role owns the full test lifecycle including development testing design verification and product validation (DV/PV) environmental and safety testing first article testing production acceptance testing test data integrity and final reporting. The manager leads engineers and technicians while remaining technically engaged ensuring testing is completed safely accurately and on schedule in a fast-moving environment with changing customer and program priorities.

Key Responsibilities

• Lead coach and develop a mixed team of test engineers and test technicians including hiring performance management technical mentoring career development and hands-on support when needed.
• Own the NPD test strategy priorities and execution plan; develop test plans procedures qualification matrices and schedules that trace to system requirements customer specifications (MIL-STD AOP STANAG) and contractual DV/PV requirements.
• Direct and when necessary participate in development qualification first article production acceptance and lot acceptance testing for energetic components including environmental (temperature/humidity vibration shock) safety (drop friction ESD thermal stability) ballistic electrical and performance testing.
• Ensure all test operations comply with explosive safety siting DoD explosives safety standards OSHA process safety management site-specific hazard classifications quantity-distance limits security requirements and approved operating procedures.
• Partner with Design Engineering Quality Manufacturing Program Management and other shared-resource organizations to translate test results into design dispositions root-cause and corrective actions (RCCA/8D) and design maturation decisions ahead of formal design reviews.
• Manage test facility fixture and equipment readiness including test bay scheduling calibration and metrology controls capital planning test-space expansion and recommendations for new or upgraded test capability.
• Own test data integrity and reporting including statistical analysis of results qualification test reports test procedures first article inspection data packages and documentation suitable for customer DCMA and government review.
• Represent Test Engineering in program reviews technical interchange meetings and issue-resolution discussions; communicate technical findings clearly to engineering teams management customers and government stakeholders as needed.
• Maintain compliance with ITAR/EAR export control requirements for all test data technical exchanges and visitor access to test facilities.
• Drive continuous improvement in test throughput prioritization fixture standardization metrology controls test automation data acquisition and reporting. Apply Lean Six Sigma statistical methods RCCA and 8D tools to reduce cycle time and prevent recurrence.
• Help shape the future organization and operating model for NPD testing including resource planning process development capacity expansion shared-equipment coordination and evaluation of emerging tools such as AI-enabled test procedure and report generation.

Required Qualifications

• Bachelors degree in Mechanical Electrical Aerospace Chemical Engineering or a closely related technical discipline. The bachelors degree is required and may not be replaced by experience alone.
• 8 years of progressively responsible test engineering experience within energetics ordnance propulsion aerospace defense or another highly regulated hardware development environment including at least 3 years in a supervisory or team-lead capacity.
• Demonstrated experience developing and executing qualification test programs against military aerospace or equivalent highly regulated specifications such as MIL-STD-810 MIL-STD-331 AOP-series MIL-DTL-23659 or customer-specific requirements.
• Working knowledge of explosive safety practices hazard classification and DoD or equivalent safety requirements within a test or manufacturing environment.
• Hands-on experience using at least one statistical analysis software package and applying statistical methods to test data such as reliability demonstration Weibull analysis design of experiments capability analysis or trend analysis.
• Experience using engineering drafting or CAD software an enterprise resource planning (ERP) system and electrical circuit simulation software such as PSpice or an equivalent tool.
• Must be a U.S. Citizen and eligible to obtain and maintain a DoD security clearance.
• Strong written verbal interpersonal and presentation skills with the ability to coach developing engineers influence cross-functional partners manage shared resources and drive decisions through organizational complexity and changing priorities.

Preferred Qualifications

• Advanced degree in a relevant engineering discipline.
• Active DoD security clearance.
• Direct experience with pyrotechnic actuator devices initiators detonators propellants airbags or other energetic-material qualification testing.
• Experience standing up or expanding physical test infrastructure including test bay design facility siting equipment acquisition capital justification and capacity planning.
• Certification or working knowledge of ISO/IEC 17025 laboratory accreditation and ANSI/NCSL Z540 calibration requirements.
• Six Sigma Green Belt or higher Lean certification formal RCCA/8D training experience with automated test systems or familiarity with AI-enabled engineering documentation tools.
• Experience with multiple statistical analysis CAD/drafting ERP circuit-simulation PLM/PDM or automated test/data acquisition platforms.

Working Conditions & Physical Requirements

• Regular presence in test bay and manufacturing environments involving energetic materials; must complete and maintain site-specific hazardous-materials explosive-safety security and access-control training.
• Ability to wear required personal protective equipment (PPE) and comply with all safety security and access-control procedures for restricted test areas.
• Occasional exposure to outdoor test-range conditions travel of approximately 10% and non-standard work hours to support critical test schedules or off-site events.

• Ability to lift up to 25 lbs and stand for extended periods during test setup and execution.

  
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