Maintenance Controller

About the Role

Dawn Aerospace is pioneering the Mk-II Aurora, a reusable, rocket-powered spaceplane meant to revolutionize space access by making it as routine as aviation. To support increasingly frequent flight operations, we seek a Maintenance Controller to lead and enhance maintenance systems, processes, and procedures ensuring safe, scalable spaceplane operations.

This leadership role within the Flight Operations team ensures that maintenance tasks are planned, executed, documented, and regulated in line with approved standards, company policies, and legal requirements.

Working closely across flight testing, engineering, maintenance, quality assurance, and certification, you will develop and implement the spaceplane maintenance program, procedures, and the authorisation framework for maintenance personnel. You will maintain competence and training standards of staff performing maintenance and oversee maintenance planning, defect management, configuration control, and the ongoing airworthiness of the aircraft.

Reporting to the Flight Operations Team Lead, this position collaborates extensively within the spaceplane program and broader organization. You'll coordinate ground operations during flight testing and play a critical role in transitioning maintenance strategy towards routine, high-frequency reusable spaceflight.

Ideal candidates possess solid technical judgement, leadership experience, and problem-solving skills, thriving in dynamic environments. You will establish systems and processes from the ground up, provide clear direction to maintenance teams, engineers, and operators, and foster a culture of accountability and continuous improvement while ensuring the aircraft remains compliant, safe, and ready for flight.

This role suits practical, organised individuals ready to take ownership in a fast-evolving setting and help define maintenance standards and culture for a new generation of aerospace vehicles.

Key Responsibilities

• Manage and oversee pre- and post-flight spaceplane activities, resolving issues to minimize operational disruptions.
• Coordinate ground operations and movements, ensuring safety, efficiency, and effectiveness.
• Act as the main contact for ground operation activities.
• Assign duties to ground crew based on task priority and skill level.
• Ensure ground crews adhere to procedures, checklists, and provide progress reports.
• Escalate problems to flight crew, primarily the Flight Director.
• Recommend improvements in procedures, equipment, and human factors to the Flight Crew and Design Engineers.
• Provide on-the-job training to crews as required.
• Ensure comprehensive record-keeping of ground activities and maintenance progress.
• Maintain availability and operational readiness of all equipment and tools.
• Supervise all maintenance activities for the Mk-II spaceplane, both scheduled and unscheduled.
• Investigate and resolve defects before releasing the aircraft for flight.
• Conduct release-to-service inspections following maintenance work.
• Develop, implement, and monitor maintenance standards for uncrewed aircraft.
• Collaborate with design engineers to create maintenance programs informed by design data.
• Ensure facilities, environment, and tools meet necessary conditions for maintenance tasks.
• Develop payload maintenance procedures alongside commercial partners.
• Create training materials and authorise maintenance staff upon competency assessment.
• Monitor and assure quality and compliance of maintenance activities.

Requirements and Experience

• Excellent organisational skills with strong attention to detail.
• Effective communication and coordination abilities across multidisciplinary teams.
• In-depth knowledge of uncrewed aircraft maintenance practices and regulatory standards, such as CAA Part 102 or equivalent.
• Practical mindset capable of refining processes without disrupting daily operations.
• Experience in research and development or flight test environments preferred.
• Keen interest in aerospace, flight testing, and innovative technologies highly valued.
• Proven experience engaging with external stakeholders including aerodrome owners, regulators, contractors, operators, and customers.

Diversity and Inclusion

Dawn Aerospace values diversity and inclusion, striving to create a supportive environment where individuals of all backgrounds and experiences can prosper and contribute their best.

About Dawn Aerospace

We are a space transportation company committed to providing sustainable, scalable access to space. Our innovations span green in-space propulsion systems, servicing refuelling capabilities for satellites, and developing fast, reusable rocket-powered aircraft to transform access to sub-orbital space.

Our global teams are located across New Zealand, the Netherlands, France, and the USA.