Principal Engineer – Materials and Process

Unleash the Power of Multi-Mission Excellence: Safeguarding the Seas for the World's Navies.

Step into a world where cutting-edge technology meets unparalleled expertise. Ultra Maritime pioneers delivering multi-mission solutions that protect and empower the naval forces worldwide. With our extensive portfolio of capabilities, our innovations are utilised on naval fleets across our allied navies around the globe.

As the maritime and underwater battlespace evolves, we tirelessly push the boundaries to develop advanced specialist systems that provide our 'five-eyes' Defence customers with an unbeatable warfighting edge. From surface vessels to sub-surface operations and unmanned platforms, we are revolutionizing the way naval missions are executed.

We thrive on collaboration and partnering with our customers to ensure mission success. Our expert solutions encompass an array of game-changing technologies, including state-of-the-art sonar, radar, expendables, signature management, and naval power systems.

Join us in shaping the future of naval warfare and together, we will safeguard the seas and empower navies worldwide!

The Principal Engineer – Materials is the technical authority for materials across Ultra Maritime’s underwater sensing portfolio, including sonobuoys, sonar systems, acoustic arrays, and ASW technologies. The role is responsible for defining, governing, and optimizing the use of ceramic, polymer, and metallic materials across pressure housings, acoustic windows, structural components, encapsulation systems, and electronic packaging operating in harsh marine environments.
The position leads material selection, qualification, modeling, and manufacturing process optimization, and drives the adoption of advanced materials and additive manufacturing (metal 3D printing) for next-generation underwater systems.

Nationality Requirements

Candidates must be eligible to obtain the relevant security clearance required for the role, due to the nature of the programmes we deliver for our customers.

Job Description

Key Responsibilities

The Principal Engineer provides technical leadership for all materials used in sonar and sonobuoy systems operating in extreme subsea conditions, including high hydrostatic pressure, corrosion, vibration, shock loading, and long-duration seawater exposure.

The role defines and owns material strategies across metallic, polymer, and ceramic systems, including corrosion-resistant alloys, structural steels and titanium, acoustic-transparent polymers, elastomers, epoxy and polyurethane encapsulants, and functional ceramics used in sensing, insulation, and acoustic applications.

A core responsibility is leading material, polymer, ceramic, and process modeling and optimization, including predictive simulation of corrosion, fatigue, fracture, viscoelastic behavior, thermal response, acoustic transmission, and manufacturing process variability. These models are used to optimize product design, improve reliability, and reduce lifecycle cost and risk.

The Principal Engineer leads end-to-end process optimization across material systems, including casting, forging, machining, ceramic processing, polymer molding, curing, adhesive bonding, coating, and encapsulation processes to ensure repeatable quality, high yield, and consistent performance.

The role defines and executes material qualification and validation strategies across all material classes, including environmental testing such as pressure cycling, thermal shock, vibration, shock, saltwater immersion, and long-duration aging to ensure compliance with defense and maritime standards.

The position leads root cause investigations of material and process-related failures, including corrosion, cracking, ceramic fracture, polymer degradation, delamination, sealing failures, and fatigue, and implements corrective and preventive actions to improve product robustness.

The Principal Engineer collaborates closely with systems engineering, acoustics, electronics packaging, and manufacturing teams to ensure material selection supports acoustic performance, structural integrity, and system reliability requirements.

The role governs supplier material and process capability across metallic, polymer, and ceramic supply chains, ensuring quality, traceability, and process control consistency for mission-critical components.

A key focus is driving innovation in ceramic, polymer, and metallic material systems, including acoustic-optimized materials, high-performance composites, advanced coatings, and environmentally resistant systems for underwater applications.

The role defines and executes the roadmap for additive manufacturing (metal 3D printing), including material qualification, process modeling, and deployment for complex geometries, lightweight structures, and sustainment/repair solutions.

Qualifications and Experience

• Master’s or PhD in Materials Science, Metallurgical Engineering, Polymer Engineering, Ceramic Engineering, Mechanical Engineering, or related discipline
• 12+ years of experience in defense, aerospace, marine, or subsea engineering environments
• Strong expertise across metallic, polymer, and ceramic material systems
• Deep understanding of corrosion, fatigue, fracture mechanics, pressure effects, and environmental degradation in seawater
• Proven experience in process optimization and manufacturing of multi-material systems
• Experience in material and process modeling (FEA, fracture mechanics, viscoelastic modeling, thermal and corrosion modeling)
• Experience with qualification and testing of mission-critical systems in harsh environments
• Exposure to sonar, underwater acoustics, or sonobuoy systems is highly desirable
• Familiarity with additive manufacturing (metal AM) and qualification frameworks is an asset

Core Competencies

• Technical authority across ceramic, polymer, and metallic material systems
• Strong capability in material and manufacturing process optimization
• Deep knowledge of corrosion, fatigue, fracture, sealing, and environmental degradation
• Experience with acoustic-sensitive and pressure-rated material systems
• Strong modeling and simulation capability for multi-material behavior
• Knowledge of manufacturing processes (ceramics, polymers, metals, coatings, bonding, AM)
• Expertise in qualification, certification, and reliability engineering
• Cross-functional technical leadership in complex engineering environments

Typically, a Bachelor Degree (or equivalent) in a related field and 12+ years experience in a range of roles within a relevant complex engineering environment. May be required to maintain security clearance.

Diverse & Inclusive Employer

Ultra Maritime is an equal opportunities employer that values diversity, inclusion, equity and equality. Underpinned by our values, behaviours, and policies, we want you to feel empowered to be your best and authentic self.

We promote a workplace that welcomes people from all backgrounds and cultures; believing that this will increase our diversity of thinking, and ultimately ensure we continue delivering on our commitments to our customers.

We do not discriminate based on race, religion, colour, national origin, gender identity, sexual orientation, age, marital status, veteran status, or disability status and welcome applications from all candidates.

What’s in it for you?

We offer a competitive benefits package including extended health and dental, life insurance, RRSP, deferred profit sharing, optional critical illness insurance, an EFAP and student bursaries

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We encourage regular manager-employee performance feedback, goal alignment and employee development through our Employee Performance Development Plan (EPDP) and offer employee education assistance to allow our people to acquire new qualifications and certifications.

We are an Equal Opportunities employer and particularly welcome applications from Women, Aboriginal Persons, Persons with Disabilities and Visible Minorities.

Reasonable accommodation statement: If you need an accommodation for any part of the application process, please email [email protected]

Company: Ultra Maritime