Zepher Flight Laboratories, Inc. (ZFL) is developing the “Z1”, a 55 pound, 14-foot span VTOL drone that is powered by hydrogen fuel cells. ZFL received a government contract in 2020 to create the Z1 prototype, and a second contract in 2022 to productize and deliver test articles to the U.S. Military. We are looking for engineers, technicians, and operators who are able and willing to push through this next phase with us. Candidates must have a good combination of skill, industry knowledge, curiosity, and drive in order to solve problems effectively and quickly.

Note: Candidates with a variety of skills and experience that fall under multiple job posts (but which may not be a perfect fit for any single one) are encouraged to apply. We'd love to chat.

Summary of Position:

The Lead Composites Technician will lead a team of fabricators that manufacture a 14-foot span carbon fiber prepreg drone. This is a key position, and this person must make themselves intimately familiar with the manufacture and finishing of all Z1 airframe components. They must improve processes on their own initiative and troubleshoot problems as they arise. The manufacturing methods have been largely proven out, but further optimization for manufacture is needed.

Other duties will include prototyping/first pulls of new parts and helping advise engineering on manufacturing methods.

Essential Duties, Responsibilities, and Skills:

• 3+ years manufacturing prepreg composite parts
• Willingness and ability to lead other technicians. Prior leadership experience is not required but is highly desirable.
• Ability to both take and provide honest feedback from/to engineering in the interest of product quality
• Experience with, and a thorough understanding of, bladder molding within 2-part metal molds heated with a press is essential
• Experience with silicone inserts/intensifiers in bladder molding applications
• Experience with custom bladders (such as silicone), single-use bladders, and expendable foam compression inserts.
• Skilled at troubleshooting failed parts and improving manufacturing processes
• Ability to write training guides and work instructions using MS Word that will be used by new fabricators (Much of these materials already exist, but more will be needed)
• A strong ability to focus on the product and the ‘big picture'. For example, this person must constantly push for manufacturing methods that can be used by beginners – not methods which can only be reliably performed by expert technicians like themselves.
• This person will take initiative, proactively solve problems, and communicate those actions to their team without supervision. If this project were a book, it would be a “choose your own adventure” not an instruction manual.

Preferred Qualifications:

• Experience molding prototype silicone inserts using wax offsets
• Experience with optimizing mold temperature ramp schedules
• Experience both with cutting table software and prepreg hand cutting methods
• Experience with and understanding of methods that produce pinhole-free parts
• Experience with core
• Experience with vinyl wrapping
• Prior experience with conventional vacuum bagging and/or resin infusion molding may be desired during prototyping but is not used for production
• Ability to lift 50 pounds

This position may require access to information that is subject to compliance with the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). To conform to the requirements of the ITAR and/or the EAR, applicant must be a U.S. citizen, lawful permanent resident of the U.S., or protected individual as defined by 8 U.S.C. 1324b(a)(3).

Zepher Flight Labs is an equal opportunity employer. Qualified candidates will be considered for employment regardless of race, color, religion, age, sex, (including pregnancy and gender identity), sexual orientation, political affiliation, national origin, marital status, medical condition, disability, genetic information, parental status, military or Veteran status.

Principals only; no agencies.