Materials & Processes Engineer – Sealants, Paints & Anti‑Corrosion (Mechanical Coupon Testing)
Bristol – Hybrid
£40,000 – £55,000
Role
The consultant will work in close collaboration with customers to support major aerospace engineering technical departments. The role focuses on the qualification, validation, and certification of surface technologies, specifically sealants, paints, and anti‑corrosion systems, with a strong emphasis on mechanical and environmental coupon testing.
The engineer will provide technical support from requirement capture through to aircraft or product implementation, operating in a dynamic, fast‑paced environment. The role involves technical leadership of qualification and test activities, coordination with laboratories and suppliers, and supporting production, certification, and in‑service topics.
Engineers are expected to manage multiple activities concurrently, applying fundamental engineering principles across materials, processes, and testing disciplines.
Key Responsibilities
The role mainly entails support to the development, validation, and qualification of sealants, paints, and anti‑corrosion systems, including:
- Capture and interpretation of design, manufacturing, and certification requirements
- Definition of technical requirements for surface technologies and protective systems
- Planning, execution, and technical oversight of mechanical coupon test campaigns, including:
- Static and durability testing
- Environmental exposure (temperature, humidity, fluids)
- Adhesion, cohesion, peel, shear, and tensile testing
- Corrosion‑related testing in conjunction with coatings and sealant systems
- Engagement with internal stakeholders, suppliers, and external laboratories to define and manage qualification and certification plans
- Technical assessment and validation of test methods, test results, and reports against applicable specifications and standards
- Support to process qualification, industrialisation, and production troubleshooting
- Review and validation of supplier data and substantiation evidence
- Contribution to material allowables, internal standards, and engineering documentation
- Consideration and follow‑up of Environmental, Health & Safety (EHS) requirements related to materials and test activities
- Ownership of assigned tasks, with structured reporting of progress, risks, and issues to relevant teams
Knowledge and Experience
Qualifications
- BEng / MEng / MSc in Mechanical, Aerospace, Materials Engineering, or a related discipline
- MSc in Material Science or Chemistry advantageous
- Relevant professional experience may be considered in lieu of formal qualifications
Required Skills & Competencies
- Experience in materials and processes engineering, with a focus on surface technologies
- Practical experience of mechanical coupon testing, test planning, and result interpretation
- Knowledge of sealants, paints, primers, and anti‑corrosion systems
- Understanding of corrosion mechanisms, surface preparation, and coating performance
- Familiarity with aerospace standards, specifications, and test methods
- Ability to technically assess and validate supplier and laboratory data
- Strong analytical and problem‑solving skills
- Project management capability – planning, prioritisation, risk and delivery
- Strong written and verbal communication skills, including technical report writing
- Customer‑focused mindset, comfortable working across multiple projects and stakeholders
Desirable Experience (any of the following)
- Aerospace or other regulated industries (e.g. defence, automotive, rail)
- Mechanical testing laboratories or industrial qualification environments
- Surface treatment and coating application processes
- Environmental durability and corrosion test methods
- Materials qualification and certification activities
- Manufacturing or shop‑floor exposure
- Failure investigation or root‑cause analysis related to coatings or sealants
Personal Attributes
- Methodical and detail‑driven approach to engineering activities
- Able to work autonomously while integrating effectively within multi‑disciplinary teams
- Comfortable balancing technical depth with programme delivery priorities
- Adaptable and versatile across related materials and testing topics
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