FSW Process Engineer

About StirLight

StirLight is a growing advanced-manufacturing business developing UK friction stir welding capability for customers across the automotive, energy, nuclear, aerospace and defence sectors. We are looking for a practical, hands-on FSW Process and Manufacturing Engineer to help develop safe, repeatable and well-documented welding processes and support controlled production activity. This is a varied role combining FSW machine operation, process development, CNC and robotic equipment, tooling and fixture design, technical analysis, testing and production delivery. It would suit someone who enjoys working directly with machinery and taking ownership of practical engineering challenges.

The role

• Set up and operate FSW machinery, tooling and fixtures.
• Plan and conduct welding trials, systematically adjusting process parameters and recording results.
• Run repeatable production cycles to approved parameters, work instructions, safety controls and quality requirements.
• Analyse process and inspection data, investigate weld defects and recommend corrective actions.
• Design practical tooling, fixtures and components using CAD.
• Support improvements to CNC, robotic and other advanced-manufacturing equipment.
• Prepare specimens and support etching, inspection, testing and metallurgical assessment.
• Produce accurate technical reports, photographs, work instructions and process records.
• Undertake routine equipment checks and maintenance.
• Take ownership of defined production-cell activities and manufacturing work packages.
• Support customer demonstrations and technical discussions.
• Share knowledge and help train future operators or junior colleagues.

About you

We are particularly interested in candidates from development, advanced-manufacturing or high-integrity production environments. You may currently work as an FSW Technician, Senior Technician, Manufacturing Engineer, Process Engineer, Production Engineer or CNC/Robotics Engineer and be ready to take broader ownership of process and production activity.

You will need:

• At least two years’ practical FSW or closely related friction-stir process experience.
• Hands-on experience of machine setup, trials, parameter development and troubleshooting—not solely routine machine operation.
• Experience analysing process data, inspection results and manufacturing defects.
• Practical experience designing or setting up tooling and fixtures.
• The ability to interpret engineering drawings and tolerances.
• CAD capability for tooling, fixtures or component design.
• Experience working with CNC, robotic or other advanced-manufacturing equipment.
• Experience taking ownership of a production cell, significant machinery or defined manufacturing work packages.
• An understanding of manufacturing safety, traceability and controlled change.
• Experience working within ISO 9001 or a comparable quality-management system.
• The ability to produce clear, accurate technical reports, work instructions and process records.
• A collaborative, practical approach and the confidence to raise concerns or recommend improvements.
• Experience within aerospace, nuclear, defence, automotive, energy or another high-integrity manufacturing sector would be advantageous.

We are more interested in your practical industrial experience, technical judgement and ability to solve real manufacturing problems than in academic credentials alone.

Working arrangements

This is a predominantly onsite role at StirLight’s Holmewood facility because it involves industrial machinery, tooling, materials, trials and production activity. Limited remote working may be agreed for suitable CAD, analysis or reporting tasks. Occasional travel to customer, supplier or partner sites may be required.

Why join StirLight?

You will join a small, ambitious engineering business where you can work across process development and production, see the direct impact of your contribution and help shape StirLight’s growing UK FSW capability. The role offers the opportunity to take ownership of meaningful technical work while continuing to develop under experienced senior technical leadership. StirLight is committed to providing an inclusive working environment and welcomes applications from candidates with different backgrounds and experiences.