NPI Engineer – Aerospace

ennifer Griffiths Recruitment are exclusively representing our client, in the search for an NPI Process Engineer to join their team in Cardiff. This role offers the opportunity to support the introduction of new components and coating processes within a specialist manufacturing environment. Working closely with engineering, production and laboratory teams, you will help develop and qualify thermal spray coating processes, support customer approvals and ensure new products are ready for efficient, consistent production. Key Responsibilities: Review customer drawings, purchase orders and technical specifications to assess feasibility, identify risks and provide accurate process costings. Develop robust thermal spray coating processes, including spray parameters, masking, fixturing and robot path requirements. Plan and manage customer qualification programmes, coordinating laboratory testing and preparing technical documentation for customer approval. Prepare First Article Inspection (FAI) reports in line with AS9102 requirements and lab reports, ensuring all supporting evidence is accurate and traceable. Produce Manufacturing Process Plans, work instructions and inspection documentation to ensure new products are ready for production. Support initial production runs, brief operators and shift leaders, and hand over qualified processes to the Production Support team. Investigate coating defects, interpret test results and lead root cause analysis and corrective actions for quality issues. Support powder and consumable selection, supplier qualification and the assessment of alternative materials. Manage new product introduction (NPI) projects, ensuring qualification activities meet agreed deadlines and budgets. Maintain audit readiness by providing evidence of process qualification and control for Nadcap, customer and internal audits. Share technical knowledge, support colleague development and work collaboratively across engineering teams. Experience: Ideally you will have: A degree, HNC or HND in Materials, Metallurgy, Mechanical or Manufacturing Engineering, or equivalent practical experience. Experience in an NPI, process or qualification engineering role within aerospace or another special-process environment (e.g. coatings, surface treatment, heat treatment or welding). A working understanding of qualification, First Article Inspection (AS9102), APQP, PFMEA and control plans. The ability to interpret metallographic and mechanical test results The ability to read engineering drawings, apply GD&T, and interpret customer and AMS specifications. A structured approach to problem solving and root cause analysis. Confident, clear written and verbal communication, including technical report writing and customer-facing discussions. Good computer literacy, including Microsoft Office and ERP/quality systems. Desirable Experience: Hands-on thermal spray process development experience (plasma, HVOF, HVAF, arc wire or flame spray). Experience qualifying coatings to aero-engine or industrial gas turbine OEM specifications. Experience working within a Nadcap-accredited coatings or special-process operation. Knowledge of associated processes such as grit blasting, heat treatment, grinding or finish machining of coatings. Design of Experiments, SPC or Six Sigma training. CAD skills (ideally SolidWorks) for fixture and masking design, or exposure to robot programming. Membership of IMechE or IOM3, or working towards Chartered Engineer status. Hours of Work: Staggered day shift pattern to support production, with working hours of either 7:00am–3:30pm or 10:00am–6:30pm. Flexibility is required to work either pattern, on a fixed or rotating basis depending on business needs. Salary: £40,000–£56,000 per annum, dependent on experience. Location: Cardiff Contract: Permanent For more information please contact [email protected] or call our office on 01656 767778.