Composite Technician

About this role

Job Title: Composite Technician

Location: North Kingstown, RI

Level: Medium

Client Facing: Yes

About PAC Group

At The PAC Group (PAC), we specialize in engineering consulting, program management, and operational excellence—delivering high-impact solutions in more than 20 countries. We’re proud to partner with the world’s leading companies in automotive, aerospace, industrial, and technology sectors, providing strategic guidance and hands-on execution that drive innovation and efficiency.

Whether we’re launching advanced manufacturing systems, deploying digital simulation tools, or scaling global operations, PAC thrives at the intersection of technology, engineering, and problem-solving.

Joining PAC means joining a dynamic, fast-paced, and global team that values curiosity, collaboration, and continuous improvement.

Role Purpose:

The Composite Technician is responsible for the hands-on fabrication, assembly, repair, and testing of advanced composite structures and components used in next-generation electrified products. This role plays a critical part in supporting prototype development, design validation, and production readiness. The ideal candidate combines deep composites manufacturing expertise with a practical, problem-solving mindset and thrives in a fast-paced startup environment where quality, safety, and innovation are paramount.

Key Responsibilities

• Fabricate, assemble, and finish composite components and structures using prepreg, wet layup, vacuum bagging, infusion, and other advanced composite manufacturing techniques.
• Perform mold preparation, material cutting, layup, curing, demolding, trimming, bonding, and finishing operations.
• Operate and maintain composite manufacturing equipment, including ovens, autoclaves, vacuum systems, trimming tools, and inspection equipment.
• Maintain cleanroom/shop standards, calibrate shop tools, and ensure safety and material handling protocols (OSHA, resin safety) are strictly followed.
• Read and interpret complex engineering drawings, CAD models, 3D piles, specifications, technical work instructions, and composite layup schedules.
• Support development, prototype, and production builds of new model.
• Collaborate with design engineers to iterate rapidly on prototype tooling, fixtures, and part modifications in a dynamic environment.
• Work closely with design, manufacturing, and testing engineers to identify and resolve build issues and improve manufacturability.
• Perform structural bonding, mechanical assembly, and integration of composite components with metallic and electrical systems.
• Trim, drill, deburr, and assemble cured composite and multi-material subassemblies to tight engineering tolerances using precision hand and power tools.
• Conduct in-process and first-article inspections using precision measurement tools (calipers, micrometers, depth gauges) to verify part geometry and structural integrity.
• Document manufacturing activities to ensure compliance with quality standards and engineering requirements.
• Identify defects and perform composite repairs as required using approved techniques and procedures.
• Maintain strict adherence to quality standards, safety regulations, and material handling procedures.
• Assist in developing manufacturing processes, tooling concepts, and build documentation for future production.
• Participate in continuous improvement initiatives focused on quality, cost, throughput, and reliability.
• Support test activities as needed, including troubleshooting and modifications.
• Required

Qualifications

• 5+ years of hands-on experience manufacturing composite structures in aerospace, defense, motorsports, marine, or other high-performance industries.
• Demonstrated experience with composite fabrication methods including:
• Prepreg and wet-layup
• Vacuum bagging and thermal/autoclave or oven curing
• Resin infusion
• Structural bonding
• Composite repair techniques
• Experience working with carbon fiber, fiberglass, honeycomb core, and sandwich-panel constructions.
• Ability to read and interpret engineering drawings, GD&T, work instructions, and process specifications.
• Proficiency using precision measurement tools and fabrication equipment.
• Strong understanding of composite materials, cure processes, and quality requirements.
• Experience maintaining accurate manufacturing records and quality documentation.
• Ability to work independently with minimal supervision while maintaining high-quality workmanship.
• Strong troubleshooting and problem-solving skills.
• High school diploma or GED required; technical/vocational certification.
• Ability to stand for extended periods, wear required personal protective equipment (PPE), lift up to 50 lbs (23 kg), and perform hands-on manufacturing activities.
• Eligibility to work in the applicable country.

Preferred Qualifications

• Experience building flight hardware for commercial, military, eVTOL, UAV, space, or advanced air mobility programs.
• Previous experience in an aerospace startup or rapid product development environment.
• Familiarity with FAA, EASA, AS9100, or equivalent aerospace quality standards.
• Experience operating autoclaves and developing composite cure cycles.
• Composite certification from a recognized technical institution or aerospace organization.
• Experience with non-destructive inspection (NDI/NDT) methods.
• Knowledge of tooling design, mold fabrication, and manufacturing process development.
• Experience integrating composite structures with electrical, battery, propulsion, or high-voltage systems.
• Ability to support prototype builds and transitions into low-rate or full-scale production.
• Lean manufacturing or continuous improvement experience.
• Basic exposure to CAD/CAM software (such as CATIA V5, SolidWorks, or AutoCAD) for reviewing ply geometries and digital models.
• Experience building composite molds, plugs, or master patterns from scratch.
• Aircraft maintenance, airframe, or aerospace manufacturing background.
• The salary range for this position is dependent upon experience, education, and qualifications.
• Pay Range