Materials and Processes Engineer (Metallurgist)

De Havilland Aircraft of Canada Limited (DHC) is a storied name in the aerospace industry, recognized worldwide for its pioneering contributions to aviation and its unwavering commitment to quality, innovation, and reliability. Headquartered in Calgary, AB, DHC currently has approximately 2,400 employees across British Columbia, Alberta and Ontario, as well as in markets and distribution hubs world-wide.

Established in 1928, De Havilland Canada has a rich history marked by the development of some of the most iconic and versatile aircraft ever built. These aircraft have served a variety of roles—from bush flying to commercial aviation—and are celebrated for their rugged durability, operational versatility, and excellence in performance.

Over the decades, De Havilland Canada has evolved to meet the changing needs of the aviation industry. Today, we are more than just an aircraft manufacturer; we are a comprehensive aerospace company with capabilities that span design, production, maintenance, repair, and overhaul (MRO) services. Our operations are supported by a team of skilled engineers, technicians, and industry professionals who are dedicated to upholding the highest standards of craftsmanship and innovation.

Position Overview

The Materials and Processes Engineer (Metallurgist) is responsible for the technical evaluation, qualification, and approval of materials and special processes used in aircraft design, manufacturing, and repair. This role ensures compliance with applicable regulatory, environmental, and airworthiness requirements, while supporting product integrity, manufacturability, and continued operational safety.

The incumbent collaborates cross-functionally with engineering, manufacturing, quality, suppliers, and external laboratories to maintain and advance materials and process capabilities in alignment with industry best practices and organizational objectives.

Key Responsibilities

Core Responsibilities

• Evaluate, qualify, and approve metallic materials and associated processes for aerospace applications, ensuring compliance with design, certification, and performance requirements.
• Lead technical assessments of new and alternative materials, working closely with material suppliers, testing laboratories, and research organizations.
• Develop, maintain, and revise material and process specifications, standards, and engineering documentation in accordance with regulatory and company requirements.
• Assess materials and processes for compliance with environmental and regulatory frameworks, including but not limited to REACH, EPA, CEPA, and other applicable standards.
• Review and approve aircraft design and repair modifications for adherence to approved materials and process requirements, ensuring continued airworthiness.
• Support the introduction and implementation of new manufacturing and special processes to maintain technological competitiveness and industry leadership.
• Provide subject matter expertise and technical support to internal stakeholders, including Manufacturing, Quality, and In-Service Engineering, for troubleshooting, failure investigations, and operator inquiries.
• Conduct supplier audits and assessments of special processes (e.g., Nadcap-accredited processes), including on-site evaluations and technical reviews.
• Evaluate supplier capability and conformity to defined manufacturing and process requirements, including approval of new suppliers and ongoing performance monitoring.
• Review and disposition supplier requests for process deviations, concessions, and non-conformances, ensuring risk is properly assessed and mitigated.

Additional Responsibilities

• Participate in continuous improvement initiatives to enhance materials performance, process efficiency, and product quality.
• Support internal and external audit activities, including regulatory authority audits and quality system assessments.
• Contribute to root cause analysis and corrective/preventive action implementation related to materials and process non-conformances.
• Stay current with advancements in metallurgy, materials science, and aerospace manufacturing technologies, recommending improvements where appropriate.
• Assist in the development of engineering best practices, lessons learned, and knowledge-sharing within the organization.
• Provide mentorship and technical guidance to junior engineers and cross-functional team members as required.
• Support airworthiness investigations, service difficulty reports, and fleet reliability initiatives.

Required Qualifications

• Bachelor’s degree in Materials Engineering, Metallurgical Engineering, or a related discipline.
• Minimum of 5 years of relevant experience in aerospace materials and processes engineering.
• Demonstrated experience with special processes used in the manufacture of aerospace metallic components, such as heat treatment, welding, chemical processing, surface treatments, and shot peening.
• Strong understanding of aerospace regulatory and quality standards, including Nadcap, AS9100, and ISO 9001.
• Knowledge of environmental and chemical compliance regulations (e.g., REACH, EPA, CEPA).
• Experience in supplier qualification, auditing, and process approval within an aerospace or highly regulated environment.
• Excellent problem-solving, analytical thinking, and decision-making skills.
• Strong project management and organizational skills, with the ability to manage multiple priorities.
• Effective communication skills, both written and verbal, with the ability to convey complex technical information clearly.
• Eligibility for registration or licensed as a Professional Engineer (P.Eng.) in Ontario.

Preferred Qualifications

• Advanced degree (Master’s or PhD) in Materials Science or Metallurgical Engineering.
• Experience supporting aircraft certification programs (e.g., Transport Canada, FAA, EASA).
• Familiarity with failure analysis techniques, including fractography, metallography, and corrosion analysis.
• Working knowledge of statistical methods and materials testing standards (e.g., ASTM, AMS).
• Experience with digital engineering tools, materials databases, or PLM systems.

Key Competencies

• Technical expertise in metallurgy and aerospace materials
• Attention to detail and commitment to quality and compliance
• Cross-functional collaboration and stakeholder engagement
• Continuous improvement mindset
• Adaptability and sound engineering judgment

Working Conditions

• Occasional travel required for supplier audits and technical reviews (domestic and international).
• Work is performed in a combination of office, laboratory, and manufacturing environments.

Why work at De Havilland?

De Havilland Canada is a Canadian-owned and operated aircraft manufacturer dedicated to providing rewarding opportunities in a diverse and welcoming workplace.

• Work with a team that makes a true difference in the world-making it possible for people to travel around the globe efficiently, comfortably and safely.
• We’ve manufactured over 5,600 aircraft including the most advanced turboprop in the air today. Our experience and expertise in constructing the highest performing aircraft in the industry is second to none.
• Our state-of-the-art manufacturing facilities are dynamic workplaces led by teams that support and encourage all employees.
• With a passionate team of innovators and a global network of support, De Havilland Canada proudly carries on it’s tradition as a leader in aerospace.

In addition to plenty of opportunities for career growth in a stimulating work environment, De Havilland Canada offers:

• Competitive wages
• Paid vacation
• Extended health benefits (medical, dental, vision, paramedical)
• Life insurance
• RRSP/DPSP Plan
• Employee and family assistance program

At De Havilland Aircraft of Canada (DHC), we are committed to protecting our people, customers, shareholders and the public through Health & Safety Excellence. As such, it is expected that all employees maintain strict adherence to Health & Safety Policies and to perform key physical tasks of the position described in the job description and interview process. This may include but is not limited to the ability to work in a variety of environmental conditions including temperature extremes, confined spaces, working at heights and with or around chemicals. Employees are expected to adhere to the use of personal protective equipment (PPE) when at work which must include but is not limited to the ability to maintain a positive fit test when mask use is required.

At De Havilland Canada, we aim to be inclusive and diverse and provide equal opportunity for employment. All qualified applicants, regardless of gender, age, race, religion, sexual orientation, and disability, are encouraged to apply. De Havilland will accommodate the needs of applicants with disabilities throughout all stages of the selection process. If you need accommodation during the recruitment process, please advise your Talent Acquisition representative. Information relating to the need for accommodation and accommodation measures will be addressed confidentially.

Any offer of employment is conditional on the completion of positive and satisfactory background checks, which may include, proof that you are legally entitled to work in Canada, professional references, verification of employment history, verification of educational background and criminal background checks.