Aerospace Quality Control Engineer

Thunderstrike Aviation is expanding its Quality function and seeking a Quality Control Engineer to support the development, verification, and production of next‑generation unmanned aerial systems (UAS under 150 kg). This role is central to ensuring product conformity, reliability, and airworthiness intent as our aircraft progress from early prototypes through operationally ready production systems.

This is a highly hands‑on position within a fast‑growing aerospace startup. You will work closely with Design, Manufacturing, and Test teams to help define, implement, and continuously strengthen quality practices while the organization, products, and processes evolve.

Role Overview

The Quality Control Engineer is embedded across the full product lifecycle, contributing from early design reviews and experimental hardware evaluations through manufacturing ramp‑up and sustained production. You will define what needs to be verified, to what extent, and against which standards, ensuring alignment with certification‑ready aerospace requirements.

As Thunderstrike Aviation grows, this role plays a key part in building inspection frameworks, quality controls, and verification practices that scale with the organization. Responsibilities will naturally evolve, requiring sound judgment, adaptability, and comfort operating in an environment where processes and systems are still being established.

What You’ll Do

🔹 Inspection & Verification

• Define inspection and verification requirements, acceptance criteria, and verification scope across products, subsystems, and processes.
• Establish incoming, in‑process, and final inspection plans aligned with engineering intent and manufacturing maturity.
• Translate engineering drawings, models, and specifications into clear, actionable inspection and verification instructions.
• Support inspectors and technicians by clarifying requirements, resolving interpretation questions, and ensuring consistent application of standards.
• Perform inspections directly when required to support early builds, investigations, or critical program needs.

🔹 Product Lifecycle & Engineering Support

• Participate early in design and development activities to identify quality, manufacturability, and conformity risks.
• Review prototype, proof‑of‑concept, and experimental hardware to assess compliance with defined requirements.
• Develop and refine inspection and verification approaches as designs transition from R&D into pilot and series production.
• Ensure inspection practices remain scalable, repeatable, and appropriate for changing production rates.

🔹 Test, Flight & Operational Readiness

• Define inspection and verification requirements supporting ground testing, environmental testing, and flight activities.
• Contribute to the development and review of test plans to ensure inspection scope, acceptance criteria, and conformity checks are clearly defined.
• Establish pre‑test, pre‑flight, and post‑flight inspection and verification criteria aligned with configuration control and airworthiness intent.
• Support test and flight activities by reviewing results, resolving discrepancies, and confirming readiness for test or operation.

🔹 Documentation & Conformity

• Prepare and maintain inspection reports, conformity documentation, and test records in accordance with aerospace requirements.
• Support and execute AS9102 First Article Inspections (FAI) and authorize hardware for production and flight.
• Support deviation, concession, and release activities with clear technical rationale and quality input.
• Maintain accurate configuration, revision, and status documentation within PLM/MRP/ERP systems.
• Identify and escalate quality risks through structured deviation and documentation processes.
• Contribute to development of compliance and airworthiness evidence packages.

🔹 Nonconformance & Root Cause Analysis

• Lead or support nonconformance (NCR) investigations, including containment actions and structured reporting.
• Conduct or contribute to root cause analyses and implement corrective and preventive actions (CAPA).
• Participate in Material Review Board (MRB) activities, providing detailed inspection data and assessments.

🔹 Continuous Improvement & Quality Culture

• Identify gaps and opportunities to enhance inspection methodology, measurement capability, and QC processes.
• Contribute to initiatives that strengthen manufacturing consistency, reduce variation, and improve overall yield.
• Support ongoing improvements to the AS9100‑aligned Quality Management System (QMS) and associated documentation.
• Additional duties as assigned

What We’re Looking For

✔ Minimum 3 years’ experience in quality control, inspection, or manufacturing quality — ideally within aerospace, defense, UAS, electronics, or other regulated industries.

✔Strong hands‑on expertise with precision measurement, inspection techniques, and aerospace documentation practices.

✔Solid understanding of AS9100, AS9102 FAI, and aerospace conformity requirements.

✔Ability to interpret complex engineering drawings, GD&T, and evolving prototype specifications.

✔Experience supporting prototype and early‑stage hardware in fast‑paced R&D or engineering environments.

✔Familiarity with configuration management principles, revision control, and engineering change processes.

✔Knowledge of gauge calibration, measurement traceability, and inspection tooling validation.

✔Experience working with PLM/MRP/ERP systems for inspection workflows and records management.

✔Understanding of composite structures, cable harnesses, avionics, and electronics workmanship standards (e.g., IPC‑A‑610).

✔Experience with flight readiness inspections and aerospace system‑level verification activities.

Key Skills

• Precision measurement & dimensional inspection
• GD&T interpretation & engineering drawing comprehension
• Prototype and R&D hardware inspection
• Composite, electronics, and harness inspection
• AS9100 / AS9102 & aerospace conformity requirements
• Non-conformance (NCR) management & root cause analysis
• Configuration management awareness
• Calibration & measurement traceability
• PLM/ERP inspection workflow proficiency
• Strong documentation discipline
• Flight readiness & system‑level inspection familiarity
• Ability to perform effectively in fast‑paced, startup‑scale aerospace environments

Apply here: Aerospace Quality Control Engineer | Thunderstrike Aviation | LinkedIn