Composite Senior Technician, Prototype (R4609)

Job Description: The Prototype Technician III at Shield AI is responsible for the precision assembly, inspection, and testing of complex early-design stage wire harnesses, PCBAs, and composite structures used in aircraft and aerospace systems. This role requires adherence to stringent quality standards, detailed technical specifications, and industry regulations (such as IPC/WHMA-A-620 and AS9100). The technician will contribute to building high-reliability products that meet the safety and performance requirements of aerospace applications. 

What you'll do:

Wire Harness / PCBA Assembly, Inspection and Testing:

Read and interpret aerospace schematics, technical drawings, and detailed work instructions. 

Measure, cut, strip, crimp, and terminate wires and cables to precise tolerances using specialized tools and equipment. 

Assemble wire harnesses, connectors, backshells, and shielding components per aerospace industry standards. 

Route wires carefully to meet form board layouts, bend radii, and environmental specifications. 

Perform board hardening and gel coating procedures 

Coordinate with Avionics team members for the successful testing and provisioning of software on to Boards

Mechanical Assembly / Composite Airframe:

Conduct engine assembly, disassembly, and integration for UAV propulsion systems. 

Perform composite assembly work including basic layup procedures, bonding, vacuum bagging, running cure cycles, etc. 

Diagnose and resolve mechanical, electrical, and performance issues 

Work closely with engineers and flight test teams to ensure system readiness. 

Quality and Compliance:

Perform visual inspections, continuity testing, and high-voltage insulation resistance testing to verify conformance to aerospace standards. 

Ensure all work adheres to IPC/WHMA-A-620 Class 3, AS9100, and other aerospace quality requirements. 

Identify and repair defects, ensuring zero tolerance for errors that could impact safety or reliability. 

Maintain traceability of all components, wires, and work performed. 

Documentation and Reporting:

Accurately complete production records, test logs, and quality assurance reports. 

Maintain detailed documentation for traceability and compliance with aerospace industry standards. 

Collaboration and Continuous Improvement:

Work closely with engineers, quality control, and production teams to troubleshoot and resolve technical issues. 

Provide feedback for process improvements and ensure compliance with lean manufacturing principles. 

Adherence to Safety Protocols:

Follow all safety regulations, including ESD (Electrostatic Discharge) prevention, PPE requirements, and cleanroom protocols where applicable. 

Maintain a clean and organized workspace in line with aerospace safety standards. 

Required qualifications:

Technical Skills: 

Strong proficiency in reading and interpreting aerospace schematics, blueprints, and work instructions. 

Experience in wire harness assembly, including crimping, soldering, and connector assembly. 

Experience handling and working with PCBAs 

Composite assembly skills including basic layup procedures, bonding, vacuum bagging, running cure cycles, etc. 

Engine assembly, disassembly, and integration 

Familiarity with aerospace-specific components such as MIL-SPEC connectors, backshells, braiding, and shielding. 

Experience with quality standards like IPC/WHMA-A-620 Class 3, AS9100, and MIL-STD requirements. 

Attention to Detail and Precision: 

Ability to work with tight tolerances and ensure 100% quality in all wire harness assemblies. 

Strong problem-solving skills for identifying and addressing manufacturing defects. 

Certifications: 

IPC/WHMA-A-620 Certification required or willingness to obtain. 

Certification in soldering to J-STD-001 standards preferred. 

Physical Requirements: 

Ability to work with small components, perform repetitive tasks, and sit or stand for extended periods. 

Good manual dexterity and hand-eye coordination.