{"id":1630841,"url":"https://alion.io/job/chromalloy-aerospace-process-engineer-injection-molding","title":"Aerospace Process Engineer - Injection Molding","company":{"id":2389079,"name":"Chromalloy","domain":"chromalloy.com","url":"https://alion.io/company/chromalloy","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Dayforce","truth_index":{"grade":"A","score":98,"open_postings":130,"ghost_share":0,"stale_share":0.077,"repost_share":0.015,"time_to_fill_p50_days":27,"computed_at":"2026-10-22T06:10:10Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"middle","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Windsor, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":74000,"max_usd":134000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":4013},"experience_years_min":3,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Siemens NX","optional":true}],"status":"live","first_seen_at":"2026-09-02T07:00:00Z","employer_posted_date":"2026-10-20","last_verified_at":"2026-10-22T18:54:46Z","board_verified":true,"closed_at":null,"days_open":50,"trust":{"level":"ok","repost_count":1,"flags":[],"days_open":49},"description":"Job Summary\nWe're looking for a Process Engineer – Injection Molding to support the repair and overhaul of critical gas turbine engine components used in commercial aerospace applications. In this role, you will develop, optimize, and sustain manufacturing processes related to resin molding, protective coatings, chemical cleaning, acid etching, and blending operations. Your work will directly improve product quality, process capability, operational efficiency, and on-time delivery of aerospace components.\n\nWork That Matters\nAt Chromalloy, your work directly supports aviation safety and reliability. Our teams repair and manufacture critical aerospace components used across the global aviation industry. Whether you're improving processes, supporting operations, solving technical challenges, or driving business performance, your contributions help keep aircraft flying safely around the world.\n\nLocation: Windsor, CT\nTravel: Occasional travel required\nSchedule: On-site \n\nWhat You’ll Be Doing\nDesign and optimize low-pressure hand-injected resin molds, including venting, flow paths, parting lines, and release features to improve part quality and process repeatability.\nDevelop and refine resin molding processes, including material selection, mix ratios, cure schedules, and manual injection techniques.\nTroubleshoot manufacturing defects such as voids, incomplete fill, shrinkage, and dimensional nonconformances, implementing corrective actions to improve quality and yield.\nProvide day-to-day engineering support for production operations, including root cause analysis, corrective actions, and continuous improvement initiatives.\nLead the design, development, procurement, and implementation of process tooling, fixtures, gauging, and equipment required to support production cells.\nEstablish and maintain process documentation, including work instructions, operating procedures, specifications, calibration instructions, and quality records.\nSupport operator training and work closely with maintenance teams to implement effective preventive maintenance programs.\nDevelop and optimize HVLP spray coating processes for aerospace-grade protective coatings.\nImprove chemical cleaning, acid etching, and surface preparation processes to enhance product quality and consistency.\nDevelop standardized blending techniques, procedures, and best practices across manufacturing operations.\nMonitor process performance and drive initiatives that improve safety, quality, delivery, and cost.\n\nWhat We’re Looking For\nBachelor's degree in Engineering or a related science-based discipline such as Materials Science, Chemistry, or Physics.\n3+ years of engineering experience in a manufacturing environment; aerospace, MRO, or gas turbine component repair experience preferred.\nExperience with low-pressure or hand-injected resin molding processes and mold design optimization.\nWorking knowledge of process development, troubleshooting, root cause analysis, and corrective action methodologies.\nExperience supporting production operations and driving continuous improvement initiatives.\nAbility to interpret technical drawings, specifications, and engineering documents.\nStrong written and verbal communication skills with the ability to collaborate across operations, quality, engineering, and maintenance teams.\n\nNice to Have\nExperience within aerospace manufacturing, repair, or overhaul environments.\nProficiency with 3D CAD modeling software such as Siemens NX.\nExperience designing tooling and fixturing for manufacturing applications.\nKnowledge of aerospace protective coating systems, including:\nPolyurethane coatings\nEpoxy coatings\nAluminized coatings\nExperience with HVLP spray equipment and process optimization.\nExperience with chemical cleaning and acid etching of aerospace alloys.\nKnowledge of aerospace blending techniques and tooling selection.\nFamiliarity with Lean Manufacturing, Six Sigma, or continuous improvement methodologies.\n\nWork Environment & Physical Requirements\nWork is performed in both office and manufacturing environments with exposure to production equipment, machinery, and industrial processes.\nRegular interaction with production areas, laboratories, and repair operations is required.\nAbility to stand, walk, bend, reach, and move throughout manufacturing facilities for extended periods.\nAbility to occasionally lift and carry up to 25 pounds.\nMust be able to wear required personal protective equipment (PPE) and comply with all safety policies and 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