Key Responsibilities and Required Skills for a Filament Winder

🎯 Role Definition

This role requires a dedicated and meticulous Filament Winder to join our dynamic manufacturing team. In this critical role, you will be responsible for setting up, operating, and maintaining state-of-the-art filament winding machines to produce high-quality composite components. You'll work with advanced materials like carbon fiber and fiberglass, following precise engineering specifications to create parts that meet stringent performance and safety standards. This is an exciting opportunity for a hands-on individual who thrives in a technical environment and is passionate about contributing to cutting-edge projects in the aerospace, defense, and industrial sectors.

📈 Career Progression

Typical Career Path

Entry Point From:

Composite Technician
CNC Machine Operator
Manufacturing Assembler

Advancement To:

Lead Filament Winder / Lead Composite Technician
Manufacturing Supervisor or Team Lead
Process Engineer

Lateral Moves:

Quality Control Inspector
R&D Technician

Core Responsibilities

Primary Functions

Set up and operate computer-controlled (CNC) and/or mechanical filament winding machines to fabricate composite parts according to engineering drawings and specifications.
Carefully prepare mandrels for the winding process, including cleaning, applying release agents, and performing any necessary pre-winding assembly.
Mix resins, catalysts, and other chemical compounds in precise ratios, ensuring proper viscosity and pot life for each production run.
Load fiber spools (carbon, glass, aramid) onto the machine creels, and meticulously thread the fibers through the delivery system and resin bath.
Monitor the winding process in real-time to ensure proper fiber tension, resin impregnation, and winding pattern adherence.
Make precise adjustments to machine parameters such as winding speed, carriage travel, and band width to maintain part quality and dimensional accuracy.
Perform in-process quality checks and visual inspections to identify and correct defects like bridging, gaps, or resin-rich/starved areas.
Safely handle and transport wound parts and mandrels to curing ovens, and operate curing equipment according to specified time and temperature profiles.
Execute post-curing operations, including mandrel extraction, part trimming, sanding, and finishing to meet final part requirements.
Read and interpret complex engineering blueprints, work orders, and technical specifications to understand part geometry and material requirements.
Maintain accurate and detailed production records, including material lot numbers, process parameters, and inspection results for full traceability.
Perform routine preventative maintenance on filament winding machines and associated equipment, such as cleaning resin baths, lubricating moving parts, and inspecting for wear.
Troubleshoot and resolve common machine malfunctions and process issues to minimize downtime and scrap rates.
Collaborate with engineering and quality assurance teams to implement process improvements and contribute to new product development.
Adhere strictly to all company safety protocols and procedures, including the proper use of personal protective equipment (PPE) when handling chemicals and operating machinery.
Manage inventory of raw materials, including fibers and resins, and report any shortages to the supply chain department.
Utilize precision measuring instruments, such as calipers, micrometers, and gauges, to verify part dimensions and ensure they meet tolerance requirements.
Operate overhead cranes, forklifts, and other material handling equipment to move large mandrels and finished parts safely.
Participate in lean manufacturing initiatives and continuous improvement events to enhance production efficiency and quality.
Support the development and refinement of winding programs by providing feedback on machine performance and part outcomes.
Ensure the work area is kept clean, organized, and compliant with 5S principles to maintain a safe and efficient production environment.
Assist in the training of new operators on machine setup, operation, and safety procedures.

Secondary Functions

Support engineering and R&D teams with ad-hoc test winding and material evaluations.
Contribute to the organization's composite manufacturing strategy by providing practical feedback on new technologies and processes.
Collaborate with quality control personnel to identify root causes of defects and implement corrective actions.
Participate in daily production meetings, safety briefings, and continuous improvement workshops.

Required Skills & Competencies

Hard Skills (Technical)

Proficiency in setting up and operating CNC filament winding machines (e.g., McClean Anderson, Entec).
Experience with composite materials, including carbon fiber, fiberglass, and various resin systems (epoxy, polyester).
Ability to read and interpret complex engineering drawings, blueprints, and technical work instructions.
Skilled in using precision measuring tools such as calipers, micrometers, and pi tapes.
Knowledge of resin mixing procedures and safe handling of chemical components.
Experience with composite curing processes and oven operation.
Basic understanding of CNC programming (G-code) and the ability to make minor program edits.
Strong mechanical aptitude for performing routine machine maintenance and troubleshooting.
Familiarity with vacuum bagging and other composite processing techniques.
Certified to operate material handling equipment like overhead cranes and forklifts.
Strong understanding of manufacturing safety standards (OSHA) and procedures.

Soft Skills

Exceptional attention to detail and a commitment to producing high-quality work.
Strong analytical and problem-solving skills to diagnose and resolve process or machine issues.
Ability to work effectively both independently and as part of a collaborative team.
Clear and effective communication skills to relay information to supervisors, engineers, and team members.
A proactive and safety-conscious mindset in all aspects of work.
Strong work ethic, punctuality, and reliability.
Ability to meticulously follow complex written and verbal instructions.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED.

Preferred Education:

Associate's Degree in a technical field or a Composite Materials Technology Certificate.

Relevant Fields of Study:

Manufacturing Technology
Composite Materials Science
Mechanical Engineering Technology

Experience Requirements

Typical Experience Range:

2-5 years of hands-on experience in a technical manufacturing environment.

Preferred:

2+ years of direct experience operating CNC filament winding machines, preferably in the aerospace, defense, or pressure vessel industry.