Senior Development Engineer - Specialising In Materials And Manufacturing

Kite Magnetics is a pioneering force in the aerospace industry, specializing in high-performance electric propulsion solutions for electric aircraft. Our groundbreaking technology, Aeroperm™, reduces energy losses by a factor of ten compared to conventional magnetic materials, resulting in smaller, lighter electric motors that extend the range and payload capacity of electric aircraft. As a global startup, we are backed by leading Venture Capital firms and are on a mission to make a substantial impact on global emissions by advancing electric aircraft technology. Join our rapidly growing team and lead the way in developing innovative aircraft propulsion systems that will shape the future of aviation.

We've developed a 120 kW electric motor for light aircraft and are now refining our second-generation system for certification and pilot-scale production in 2024. We're expanding our team and inviting those with expertise in mechatronics, manufacturing, and high-powered machinery to join us. Located in the Monash Technology Precinct, just 25 minutes from Melbourne in Notting Hill, Victoria, we're eager to hear from you.

As a Senior Development Engineer at Kite Magnetics, you will lead in the development, optimization, and integration of groundbreaking technologies, including our Aeroperm™ nanocrystalline magnetic material and advanced electric propulsion systems. Reporting directly to the CEO, you will play a crucial role in refining our electric propulsion technologies for certification and large-scale production, while also spearheading the mechanical design of our next-generation systems. Your contributions will significantly impact the future of aviation, pushing the boundaries of electric aircraft performance and sustainability.

Key Responsibilities:

· Lead the ongoing development, optimization, and integration of Aeroperm™, ensuring it meets aviation certification standards for large-scale production.

· Oversee the mechanical design, development, and Manufacturing processes of our electric propulsion systems, with a focus on material selection, vibration analysis, structural integrity, and rotor dynamics.

· Conduct rigorous material qualification tests, both internally and with external laboratories, to align with aviation certification requirements.

· Collaborate closely with cross-functional teams, including motor development, electronics, mechatronics, and software, to enhance system performance and integration.

· Participate in the scale-up process of Aeroperm™ production, ensuring consistency, quality, and adherence to industry standards.

· Mentor and guide engineers within the mechanical and materials engineering domains, fostering knowledge sharing and technical excellence.

Requirements

· Bachelor’s or Master’s degree in Materials Engineering, Materials Science, Physics with a strong foundation in the principles of metallurgy and materials science.

· Minimum of 10-15 years of professional experience in mechanical engineering and materials engineering, with a specialized focus on rotating machinery design, and the application and processing of advanced materials.

· Demonstrated expertise in metallurgical failure analysis, engineering calculations, finite element analysis (FEA), computational fluid dynamics (CFD), and multi-body simulation (MBS) analysis, leveraging tools such as ADAMS, SolidWorks, and ANSYS for predictive simulation and design optimization.

· Proven capability in developing, standardizing, and managing material libraries for engineering applications, along with extensive experience in material qualification testing and failure investigation to support rigorous certification processes.

· Comprehensive understanding of manufacturing engineering practices, including CNC machining, manual machining, welding, stamping, forging, and casting, with a particular emphasis on aerospace component production and quality control.

· Significant experience in design for manufacturing (DFM), design failure mode and effect analysis (DFMEA), and root cause analysis, ensuring product reliability and compliance with stringent aviation standards.

· Proficiency in CAD software for high-quality part and drawing creation, coupled with a solid grasp of simulation software for thermal, fluid dynamics, and mechanical stress analysis.

· Strong leadership skills, with the ability to mentor and guide junior engineers, manage cross-functional teams, and collaborate effectively within a dynamic, interdisciplinary environment.

· Experience in the setup and management of testing protocols and inspection techniques, including design of experiments (DOE), coordinate measuring machines (CMM), magnetic particle inspection, and dye penetration testing, to ensure product integrity and compliance with industry standards.

· A passion for sustainable technology and a commitment to advancing the field of electric aviation, underpinned by a practical understanding of the challenges and opportunities in electric propulsion system development.

· Exceptional collaborative skills, with a proven track record of working effectively in a dynamic, cross-functional team environment, and the ability to communicate complex technical concepts clearly and effectively to a broad audience.

Other Useful Experience:

· Additional qualifications that are highly regarded include experience with thermal analysis, stress testing, balancing, bearings, lubrication, and especially experience in the design and application of nanocrystalline materials.

· An active interest or certification in private piloting is seen as beneficial, providing firsthand insights into the operational aspects and performance requirements of aircraft, which could enrich the development and optimization of electric propulsion systems.