Senior Special Processes Engineer

ABOUT EDGE

At EDGE bold ideas are engineered into technologies that protect, improve and save lives.

Headquartered in the United Arab Emirates, EDGE is a leading advanced technology group working at the forefront of defence and emerging technologies. Spanning more than 35 specialised companies and multiple centres of excellence, we are purpose-built to move fast. Free from heavy legacy processes, we give our people the autonomy, accountability, and agility to bring breakthrough technologies from concept to reality.

Based in Abu Dhabi, a globally connected hub at the crossroads of Europe, Asia, Africa, and the Middle East, EDGE is home to a truly multicultural community where bold ideas thrive, and the future is shaped.

Together, we are shaping the future.

ABOUT THE ROLE

The Special Processes Senior Engineer is a senior technical and team-leading role responsible for developing, qualifying, and industrializing critical aerospace special processes supporting Powertech’s propulsion programs, including turbofan, microjet, and piston engines.

The role acts as the technical authority for special process technologies, supporting greenfield manufacturing setup, New Product Introduction (NPI), production industrialization, and process capability development. The Senior Engineer works closely with Manufacturing Engineering, Design Engineering, Quality, Supply Chain, suppliers, equipment vendors, and technology partners while providing day-to-day technical leadership to engineers and technicians within the special processes team.

RESPONSIBILITIES

Special Process Development & Industrialization

• Lead the development, qualification, and continuous improvement of aerospace special processes for rotating, structural, and hot-section engine components.
• Provide technical leadership in processes including:

• • Shot peening
  • Thermal spray coatings (HVOF, plasma spray, wear-resistant and environmental coatings)
  • Heat treatment, vacuum heat treatment, solution treatment, aging, and stress relief
  • Brazing
  • Surface preparation, grit blasting, masking, and finishing processes
  • Cleaning
  • Chemical processing

• Define and review manufacturing routings, process specifications, work instructions, control plans, and acceptance criteria.
• Establish process capability requirements and statistical monitoring methods to ensure stable and repeatable production performance.
• Lead process validation activities including First Article Inspection (FAI), industrial qualification, capability studies, and production readiness reviews.

Greenfield Manufacturing Capability Development

• Support the establishment of in-house special process capabilities, including facility layout, equipment specification, supplier selection, commissioning, and process qualification.
• Define equipment requirements, utility needs, process controls, and environmental requirements for new special process cells.
• Support make-versus-buy evaluations and phased capability development strategies aligned with product and production roadmaps.
• Coordinate technology transfer activities from external partners and suppliers into Powertech manufacturing operations.

NPI & Program Execution

• Lead special process engineering activities during New Product Introduction (NPI) from prototype development through production readiness.
• Support manufacturing planning, process qualification, and production ramp-up activities for new engine programs and component families.
• Act as the special process focal point for assigned engine modules, components, and development programs.
• Ensure process readiness aligns with program schedules, quality requirements, and certification objectives.

Design-to-Manufacture & Concurrent Engineering

• Support concurrent engineering activities with design teams to ensure components are optimized for manufacturability, process capability, durability, and cost.
• Provide technical input during design reviews, material selection activities, tolerance allocation, coating requirements.
• Identify and mitigate manufacturing and process qualification risks early in the product development lifecycle.
• Support development of process specifications and special process requirements for new component designs.

Supplier & Partner Technical Support

• Provide technical oversight and support to special process suppliers, subcontractors, and manufacturing partners.

• Lead supplier process reviews, technical audits, qualification activities, and process improvement initiatives.
• Support supplier industrialization and process capability assessments.
• Drive resolution of process-related technical issues across the supply chain.

Technical Leadership & Team Support

• Provide technical leadership, mentoring, and day-to-day guidance to special process engineers and technicians.

BASIC QUALIFICATIONS

• Bachelor’s or Master’s degree in Mechanical Engineering, Materials Engineering, Aerospace Engineering, Manufacturing Engineering, or related discipline.
• 8+ years of experience in aerospace manufacturing, with significant experience in special process development and industrialization.
• Strong hands-on expertise at least two or more of the following aerospace special process technologies: shot peening, thermal spray coatings, heat treatment, brazing, chemical processing.
• Proven experience supporting New Product Introduction (NPI), industrialization, process qualification, and production ramp-up activities.
• Experience developing process specifications, qualification plans, control plans, and process validation documentation.
• Working knowledge of aerospace materials including titanium alloys, nickel-based superalloys, stainless steels, aluminum alloys, and high-temperature materials.
• Familiarity with aerospace quality systems, process qualification methodologies, and special process accreditation requirements.
• Experience leading technical activities, mentoring engineers, and providing day-to-day technical guidance.
• Ability to work effectively with design, quality, operations, supply chain, partners, and equipment vendors in a concurrent engineering environment.

Must-Have Competencies

• Proven hands-on special process development, qualification and industrialization experience specifically for aero-engine component manufacturing, including rotating, structural and hot-section components.
• Strong technical expertise in at least two aero-engine manufacturing special processes, such as shot peening, thermal spray coatings (HVOF/plasma), heat treatment.
• Demonstrated experience developing and executing special process qualification plans, process specifications, manufacturing instructions, process controls and validation activities for aero-engine components.
• Practical experience in aero-engine NPI, process capability development, equipment trials, process commissioning and manufacturing readiness.
• Strong knowledge of aero-engine materials, including nickel-based superalloys, titanium alloys and high-temperature steels, together with relevant OEM process specifications and NADCAP requirements.

PREFERRED QUALIFICATIONS

• Master’s degree in Mechanical Engineering, Materials Engineering, Aerospace Engineering, Manufacturing Engineering, or related discipline.
• 12+ years of experience in aerospace manufacturing, with significant experience in special process development and industrialization.

WHY CHOOSE EDGE

Launched in November 2019, the UAE's EDGE is one of the world's leading advanced technology groups, established to develop agile, bold and disruptive solutions for defence and beyond, and to be a catalyst for change and transformation. It is dedicated to bringing breakthrough innovations, products, and services to market with greater speed and efficiency, to position the UAE as a leading global hub for future industries, and to creating clear paths within the sector for the next generation of highly skilled talent to thrive.

At EDGE, the real investment goes beyond compensation. Through our dedicated learning academy and digital learning platforms, employees have access to extensive opportunities to develop new skills, deepen their expertise, and advance their careers. Combined with the freedom to innovate, strong career support, and the opportunity to collaborate with world-class talent from across the globe, EDGE is a place where you can continue to grow, keep learning, and turn ambitious ideas into meaningful outcomes.

Working at EDGE also comes with a package that genuinely reflects how much we value our people. Salaries are highly competitive and tax-free and, depending on your role and seniority, benefits can include family visas, annual flight tickets, medical insurance for you and your dependents, and education allowances for your children.

CANDIDATE PRIVACY & EQUAL OPPORTUNITY STATEMENT

If you feel your skills, experience and potential are a strong match for a role, we encourage you to apply even if you don’t meet every requirement. We are genuinely interested in what you can bring to EDGE.

Any information you share as part of your EDGE candidate profile or job application will be handled in accordance with applicable data protection and privacy regulations.

EDGE is an equal opportunity employer committed to building a diverse, inclusive, and high-performing workforce. We believe every individual deserves to be treated with fairness, respect and dignity, and our employment decisions reflect that. We do not discriminate based on race, colour, nationality, ethnicity, religion, gender, marital status, age, disability, pregnancy or parental status, or any other characteristic protected by applicable law.

As a global organisation, effective collaboration across international teams is central to how we work, so English proficiency is required for all roles unless otherwise stated in the job posting.

Please note that EDGE does not accept unsolicited resumes from recruitment agencies. Any resumes in the absence of a formally executed agreement in place will be deemed the property of EDGE, and no placement fees or compensation will be payable in respect of such submissions.