The posting
Job Summary
We are seeking a motivated and practically minded Composites Manufacturing Engineer to join our growing composites manufacturing team at Zenvo Automotive.
Reporting to the Head of Composites, this role will focus on translating engineering designs and requirements into practical, repeatable and capable manufacturing processes for our carbon fibre components.
As Zenvo develops its in-house composites capability, we are progressively introducing more complex components and expanding the range of processes within our facility. The successful candidate will play an important part in supporting this growth, working closely with Engineering and the production team to establish how components can be manufactured consistently and to the required standards.
This is a hands-on manufacturing engineering role, suited to someone who enjoys working between design and production, solving practical challenges and seeing their work implemented on the workshop floor.
We are looking for someone with a sound technical understanding of composites manufacturing, a structured approach to problem solving and the willingness to help us develop our processes and capabilities as the business grows.
Key Responsibilities
Manufacturing Process Development
- Translate engineering designs, specifications and requirements into practical manufacturing processes for carbon fibre and composite components.
- Develop and maintain manufacturing work instructions, process sequences and supporting production documentation.
- Define manufacturing requirements for mould preparation, lay-up, vacuum bagging, curing, demoulding, trimming and finishing.
- Work closely with production technicians to develop, test and refine manufacturing methods.
- Support the introduction of new composite components and processes into the facility, ensuring they are practical, repeatable and capable of meeting quality requirements.
- Identify opportunities to improve manufacturing efficiency, process consistency and component quality.
Engineering and Production Integration
- Work with Engineering to review component designs and provide feedback on manufacturing feasibility and Design for Manufacture (DFM).
- Interpret engineering data and support the translation of design information into manufacturing requirements, including BOM structures and production operations where applicable.
- Support the transition of components from prototype development into controlled production processes.
- Work alongside the Composite Production Lead and technicians to resolve manufacturing challenges and ensure processes can be followed consistently.
- Support the investigation of production issues, helping identify root causes and implement effective process improvements.
- Ensure manufacturing methods remain aligned with approved engineering specifications and quality requirements.
Tooling, Equipment and Facility Development
- Support the definition and introduction of tooling, jigs, fixtures and manufacturing equipment required for composite production.
- Provide technical input into workshop layouts, equipment positioning and material flow to improve production efficiency.
- Assist in establishing process requirements for new manufacturing capabilities and increasingly complex components.
- Work with the Head of Composites and production team to identify practical facility and process improvements.
Quality and Process Control
- Develop clear process controls and manufacturing documentation to support consistent component quality.
- Support the definition of inspection points, traceability requirements and production records.
- Work with Quality to identify recurring manufacturing issues and implement improvements.
- Support process trials and validation activities to confirm that manufacturing methods can consistently achieve the required results.
- Capture lessons learned and incorporate improvements into manufacturing instructions and processes.
Qualifications and Experience
- A degree or technical qualification in Mechanical Engineering, Manufacturing Engineering, Materials Engineering or a related discipline, or equivalent relevant practical experience.
- Experience in composites manufacturing or manufacturing process development, ideally within automotive, motorsport, aerospace or a similar industry.
- Good understanding of carbon fibre manufacturing processes, including prepreg lay-up, vacuum bagging, curing and composite finishing.
- Ability to interpret engineering drawings, technical specifications and manufacturing requirements.
- A practical understanding of tooling, fixtures and manufacturing process control.
- Experience developing work instructions or manufacturing documentation would be advantageous.
- Familiarity with CATIA, 3DEXPERIENCE or similar CAD/PLM systems would be beneficial.
- Experience supporting the introduction of new components or processes into production is an advantage.
We welcome applications from engineers with relevant manufacturing experience, as well as technically capable individuals with a strong practical composites background who are looking to develop further within manufacturing engineering.
Personal Attributes
At Zenvo, technical ability matters, but so does the attitude you bring to developing our manufacturing operation.
We are building our production capability alongside the vehicles themselves. This means we need people who are comfortable working in a developing environment and enjoy contributing to practical improvements.
We particularly value:
- Practical problem solving: Someone who can take an engineering requirement, understand the manufacturing challenges and work with others to develop a sensible solution.
- Adaptability and flexibility: Comfortable working in an environment where manufacturing processes and capabilities are continuing to evolve.
- A hands-on approach: Willing to spend time in the workshop, understand the challenges faced by technicians and ensure engineering solutions work in practice.
- Resilience and determination: Able to work through technical challenges and setbacks constructively, maintaining focus on finding a workable solution.
- Team mentality: Enjoys collaborating with Engineering, Quality and Production, recognising that successful manufacturing processes depend on input from the people who use them.
- Initiative and ownership: Takes responsibility for progressing tasks, identifying improvements and following solutions through to implementation.
- Attention to detail: Understands the importance of accurate documentation, process discipline and consistent quality when manufacturing high-performance composite components.
What to Expect
Zenvo is continuing to develop its composites manufacturing capability, with the ambition to produce an increasing range of complex, high-quality components in-house.
This role offers the opportunity to help shape how those components are manufactured, working directly with the people responsible for designing and producing them.
Not every process will be fully established, and there will be challenges as we introduce new capabilities. You will be supported by the Head of Composites and work closely with an experienced production team to develop practical solutions.
We are not expecting someone to arrive with all the answers. We value technical knowledge, a willingness to learn and the ability to turn good ideas into working manufacturing processes.
If you enjoy bridging the gap between engineering and production, take pride in developing practical manufacturing solutions and want to contribute to building a growing composites operation, we would be pleased to hear from you.
