Senior Engineer

Job Title: Senior Aerospace Engineer – PMA & Component Design

Company Overview

Air Alliance, Inc. is a growing, woman-owned aerospace MRO company specializing in the overhaul and repair of high-pressure turbine (HPT) blades and hot section components for CFM56, IAE V2500, and similar engines. We hold existing FAA repair approvals and are actively expanding our PMA (Parts Manufacturer Approval) portfolio with innovative proprietary repair processes, including our nano-weld technology for superior blade tip durability.

Position Summary

We are seeking a Senior Aerospace Engineer with strong aerospace component design experience to lead PMA development and approval activities. This role will focus on designing and validating repair solutions, preparing technical data packages, and securing FAA Parts Manufacturer Approvals (PMA) to expand our approved repair capabilities and support business growth.

Key Responsibilities

• Lead the design, analysis, and validation of repair processes for HPT turbine blades and hot section components to support new and amended FAA PMA applications.
• Develop comprehensive technical data packages including engineering drawings, material and process specifications, test plans, substantiation reports, and compliance matrices for PMA submissions.
• Perform component design, stress analysis, FEA, and metallurgy evaluations to demonstrate equivalence or superiority to OEM standards.
• Coordinate with the FAA (ACO, MIDO, or designee) on PMA projects, respond to requests for additional information (RAIs), and support audits.
• Collaborate with the shop team to implement, test, and document new PMA-approved repair processes (welding, blending, coating, dimensional restoration, etc.).
• Support 8130-3 release and ongoing production conformity for PMA parts.
• Drive continuous improvement of existing repairs and expansion into new part numbers and engine platforms.
• Mentor junior engineers and contribute to building the engineering team.
• Ensure all work complies with FAA Part 21, Part 145, and related regulations.

Qualifications & Requirements

• Bachelor’s degree in Aerospace, Mechanical, Materials Engineering, or related field (Master’s preferred).
• Minimum 8–10+ years of aerospace engineering experience with direct involvement in FAA PMA development or major repair approvals.
• Strong background in aerospace component design, particularly turbine blades or hot section hardware.
• Proven track record preparing and obtaining FAA PMA or equivalent technical approvals.
• Proficiency in CAD (SolidWorks preferred), FEA, and engineering analysis tools.
• In-depth knowledge of superalloys, welding processes, coatings, and repair methodologies.
• Experience with FAA regulatory requirements (Part 21 Subpart O for PMA) and interaction with FAA personnel.
• Excellent technical writing and project management skills.
• U.S. Person status required (ITAR compliance).

Preferred Qualifications

• Prior PMA success on turbine blades, blades tips, or hot section components.
• Experience with CFM56 or IAE V2500 platforms.
• Familiarity with additive manufacturing and 3D printing for tooling/fixturing.
• Background in MRO or aftermarket parts manufacturing.

What We Offer

• Competitive base salary + performance bonuses tied to successful PMA approvals and milestones.
• Opportunity for equity/royalty participation in new PMA repairs.
• Comprehensive benefits including health insurance, 401(k), generous PTO, and professional development support.
• Direct impact on company growth through expanding our FAA-approved repair portfolio.