Process Engineer - Thermal Spray

Job Title: Process Engineer (Thermal Spray)

Classification: Full-time, Salaried Exempt

Reports To: General Manager

Location: Kymera – CASL Houston and Thermal Spray Solutions Locations (Travel Required)

ABOUT THE COMPANY:

Kymera International is a leading global producer of specialty metal powders, pastes, and granules, catering to industries such as aerospace, defense, automotive, and electronics. Our mission is to drive innovation while adhering to the highest standards of sustainability, operational excellence, and ethical business practices. We are committed to continuous improvement and regulatory compliance on a global scale.

Job Overview:

The Thermal Spray Process Engineer plays a critical dual role in managing and optimizing technical operations for shipboard and shop projects, from initial proposals through project closeout. This position combines process engineering expertise—particularly in thermal spray technologies—with project engineering responsibilities, including design layout, estimating, and execution oversight. The engineer ensures that projects are accurately scoped, technically sound, and delivered on time, within budget, and in compliance with quality, safety, and customer specifications.

Duties and Responsibilities:

• Collaborate with Sales and Marketing to review project proposals and scopes as outlined in
• Requests for Proposal (RFQ).
• Develop detailed project layouts, schedules, and workflows for efficient execution.
• Read and interpret blueprints and technical drawings; utilize CAD software for tooling and project overlays.
• Develop Process Control Plans (PCPs) including documentation and drawings, creating a catalog aligned with product lines.
• Create user and training manuals based on PCPs to support workforce knowledge and project execution.
• Implement new product introductions, including tooling design and robotic programming where applicable.
• Lead software integrations related to process control, estimating, budgeting, and inspection.
• Support estimating efforts, ensuring accurate calculation of hours, materials, tools, equipment, personnel, and subcontractor requirements.
• Evaluate customer requirements and technical drawings to develop precise quotes and job estimates.
• Design, refine, and document thermal spray (HVOF, plasma, arc spray, grit blast), machining, and auxiliary processes to improve quality, efficiency, and consistency.
• Serve as the technical subject matter expert for all thermal spray systems and associated equipment.
• Conduct root cause analyses and implement corrective actions to optimize production workflows and coating quality.
• Manage vendor relationships for process equipment, raw materials, and upgrades.
• Troubleshoot and lead upgrades to equipment and systems to enhance reliability and capability.
• Maintain detailed technical documentation, process instructions, and job travelers.
• Train and mentor operators and technicians on process execution, troubleshooting, and safety
• compliance.
• Ensure technical training and compliance to meet business objectives.
• Drive enhancements in quality, health, and safety (EH&S) standards.
• Develop team performance metrics and support cross-departmental process controls.
• Adapt to changing business priorities and undertake other duties as assigned.
• This role may have supervisory responsibilities in the future.

Benefits Summary:

At Kymera International - we provide a competitive benefits package to support your health, well-being, and financial security, including:

• Generous Time Off: 11 annual company-paid holidays and flexible PTO.
• Healthcare Savings: Flexible Spending Accounts (FSA), Health Savings Accounts (HSA), and comprehensive dental and vision coverage.
• Retirement Support: 401(k) plan with a competitive company match.
• Insurance Coverage: Company-paid short-term disability and life insurance, with additional voluntary options like critical illness, hospital care, and long-term disability coverage.
• Competitive pay.
• Team Benefits: A supportive team culture and resources to help you thrive.

We are dedicated to helping you live your best life, both professionally and personally. Benefits are reviewed annually.

Required Skills and Abilities:

• 5+ years of technical planning, process, and project engineering experience.
• Strong knowledge of thermal spray technologies, process parameters, and equipment setup.
• Proficiency with CAD software and Microsoft Office Suite.
• Ability to manage multiple priorities in a fast-paced, deadline-driven environment.
• Exceptional analytical and problem-solving skills with a continuous improvement mindset.
• Excellent written and verbal communication skills for collaboration with teams and customers.
• Ability to thrive in a dynamic, flexible work environment where roles may blend across functions.
• Experience with estimating, project scheduling, and resource allocation.
• Must be a "US Person" under ITAR requirements and able to pass all necessary background checks and security clearances, including DBIDS credentialing.
• Possess and maintain a valid driver’s license with a satisfactory driving record, to operate a rental or company vehicle.
• Ability to travel to domestic and international up to 50%.

Required Experience and Education:

• Bachelor’s or Associate degree in Mechanical Engineering, Manufacturing Engineering, or related field, or equivalent experience.
• Minimum 5 years’ experience in manufacturing, machining, thermal spray process engineering, or project engineering roles.
• Experience in job shop or service-oriented, high-mix/low-volume production preferred.

Physical Requirements:

• Ability to stand, walk, and perform repetitive manual tasks for extended periods.
• Strength to lift, carry, push, or pull up to 50 pounds unassisted.
• Capability to perform physical tasks such as bending, kneeling, crouching, and reaching.
• Coordination and manual dexterity to safely operate machinery, tools, and equipment while maintaining focus on ergonomics and safety.
• Ability to work safely in environments with potential exposure to dust, fumes, and noise.
• Ability to wear and work comfortably in required personal protective equipment (PPE) including but not limited to steel-toe boots, for prolonged periods.

When requested by employees, and when possible, reasonable accommodations may be provided to help individuals with disabilities perform their essential job functions. Kymera is an Equal Opportunity Employer, encouraging diversity in the workplace. EOE: race/color/religion/sex/sexual orientation/gender identity/national origin/disability.