Materials & Process Development Engineer - Specialising in Amorphous Nanocrystal - Notting Hill, Australia - Kite Magnetics

Description

About Kite Magnetics:

Kite Magnetics is a pioneering force in the aerospace industry, specializing in high-performance electric propulsion solutions for electric aircraft. Our groundbreaking technology, AeropermTM, 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.

About the role:

As a Materials & Process Development Engineer at Kite Magnetics, you will lead in the development, optimization, and integration of groundbreaking technologies, including our AeropermTM nanocrystalline magnetic material. 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 development and characterization of amorphous nanocrystalline Fe-B alloys, ensuring adherence to industry standards.

· Lead the development of novel annealing techniques to refine properties and performance of Aeroperm.

· Direct the development and analysis of composite materials, particularly focusing on the lamination of soft magnetic cores.

· Oversee the production processes for amorphous metal alloys, optimizing for efficiency and quality.

· Develop soft magnetic materials for electric propulsion systems, aligning with rigorous engineering and certification standards.

· Design and refine manufacturing processes for amorphous nanocrystalline alloys to meet production scalability and quality requirements.

· Develop and manage the production process for soft magnetic cores, ensuring optimal performance and reliability.

· Implement design for manufacturing (DFM), conduct design failure mode and effect analysis (DFMEA), and perform root cause analysis to maintain product reliability and standards compliance.

· Manage the setup and execution of testing protocols and inspection techniques, ensuring product integrity and industry standards adherence.

· Conduct data-driven approaches and integrated computational materials engineering (ICME) in new material development.

Requirements

· Bachelor's or Master's degree in Materials Engineering, Materials Science, or Data Science, with a solid foundation in metallurgy and materials science.

· 1-5 years of professional experience in materials science and engineering, focusing on the development and application of novel materials.

· Proficiency in developing, characterizing, and producing amorphous nanocrystalline Fe-B alloys.

· Demonstrated experience in developing production machines for automating novel metallurgical and materials production processes.

· Expertise in the production of amorphous metal alloys and the creation of soft magnetic materials for electric propulsion systems.

· Strong capability in designing and refining processes for manufacturing amorphous nanocrystalline alloys and innovating lamination processes for soft magnetic cores.

· Demonstrated expertise in metallurgical failure analysis and engineering calculations, including FEA, CFD, and MBS, using tools like CALPHAD, SolidWorks, and ANSYS for simulation and design optimization.

· Proven experience in developing and managing material libraries, conducting material qualification testing, and failure investigation to support certification processes.

· Comprehensive knowledge of manufacturing engineering practices in aerospace component production and quality control, including CNC machining, welding, and forging.

· Proficiency in CAD and simulation software for part creation and analysis, with experience in DFM, DFMEA, and root cause analysis to ensure aviation compliance and reliability.

· Skilled in setting up testing protocols and inspection techniques such as DOE, magnetic particle inspection, and dye penetration testing to uphold industry standards.

· Experience with developing and analysing new materials using data-driven approaches and integrated computational materials engineering (ICME).

· Experience in continuous ultra-rapid annealing of novel alloys.

· Experience with composites, particularly in the lamination of soft magnetic cores.

· A passion for sustainable technology and electric aviation, with an understanding of the sector's challenges and opportunities.

· Exceptional collaborative skills, able to work effectively in cross-functional teams and communicate complex technical concepts clearly 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.