Hermeus is a venture-backed defense aviation company reclaiming the lost art of rapid iterative prototyping to build the fastest aircraft in the world today. By prioritizing relentless hardware iteration, we deliver high-speed systems at the pace of the modern battlefield. We work with the Department of War to provide the high-speed capabilities our nation and its allies need to maintain a durable, asymmetric advantage.
As a Welding Manufacturing Engineer, you will play a critical role in enabling rapid development, fabrication, and integration of advanced hardware across our R&D and prototype manufacturing environments. You’ll be responsible for developing weld processes, fixtures, and joint designs that bridge early design concepts to flight-ready hardware. This position is hands-on and deeply cross-functional, working directly with design, manufacturing, and test teams to bring complex systems from concept to reality.
Responsibilities
Develop, qualify, and optimize weld processes and parameters for multiple techniques including, but not limited to, electron beam, laser beam, gas tungsten arc, gas metal arc, plasma arc, resistance, friction-stir, and orbital tube welding.
Support R&D and production builds of welded aircraft structures, tanks, and propulsion assemblies, providing direct guidance to technicians and manufacturing engineers.
Collaborate with design and manufacturing engineering to drive weld joint design, fixture development, and assembly methods optimized for manufacturability, precision, and repeatability.
Lead root cause investigations related to weld performance, material compatibility, and process deviations; implement corrective actions based on metallurgical and mechanical findings.
Plan and execute weld qualification campaigns, including mechanical testing, NDE inspection, and data interpretation.
Partner with NDE specialists to evaluate weld quality and develop advanced inspection techniques tailored for high-performance aircraft applications.
Implement process control improvements using feedback from weld tests, NDE, and production data to increase reliability and consistency.
Identify and integrate automated or robotic welding solutions to improve throughput, consistency, and quality.
Research and evaluate emerging welding technologies and materials for potential application in hypersonic vehicle manufacturing.
Collaborate closely with tooling, automation, and integration teams to develop solutions that minimize distortion, improve accuracy, and accelerate production timelines.
Basic Qualifications
Bachelor’s degree in Mechanical Engineering or other related technical discipline.
Hands-on fabrication, manufacturing, or testing experience with welded aerospace assemblies.
Strong understanding of weld design principles and mechanical tolerances under thermal and structural loads.
Preferred Skills and Experience
Master’s degree in Welding Engineering or related technical field.
Hands-on welding experience with nickel-based alloys, stainless steel, titanium, copper, and aluminum.
Experience with brazing, joining, and metallographic interpretation.
Deep understanding of welding processes including, but not limited to, electron beam, laser beam, plasma arc, resistance, friction-stir, gas tungsten arc, and gas metal arc.
Robot programming experience for automated welding applications.
Tooling design experience for welded assemblies to minimize distortion and improve repeatability.
Knowledge of weld strength testing methodologies, standards, and data acquisition systems (ASTM E8, E399, E740, ISO 15653, AWS D17.X, AWS C7.X, thermocouples, strain gages, etc.).
Experience performing root cause analysis and corrective actions using techniques such as optical and SEM fractography, hardness testing, chemical analysis, and mechanical testing.
Demonstrated success applying Design for Manufacturability (DFM) principles to transition welded designs from prototype to production.
Strong ability to multi-task, prioritize, and communicate results across engineering, manufacturing, and leadership teams.
Highly detail-oriented with excellent documentation and organizational skills.
Proven track record of success in fast-paced, high-growth, technically demanding environments.
Additional Requirements
Must be willing to work extended hours and weekends as needed to support build schedules and testing operations.
Occasional travel may be required to support suppliers or test campaigns.
Ability to perform hands-on work in fabrication and prototype build environments, including climbing, lifting, and working in confined areas as required.
Desire to be part of a high-intensity, mission-focused team driving innovation in hypersonic aircraft development.