Hello and welcome to my site! I’m Chas Prebil, an engineering leader with over 20 years of experience in aerospace, defense, and advanced materials development. Through my new venture, Chas Prebil Enterprises LLC, I’m excited to share insights, lessons learned, and forward-thinking ideas from my career while offering consulting services to the aerospace and defense industries. Whether you’re an engineer, a business leader, or simply curious about cutting-edge technology, I hope this space inspires and informs.

My journey in engineering began with a B.S. in Aerospace Engineering from the University of Illinois at Urbana-Champaign, followed by an M.S. in Mechanical Engineering and a Professional MBA from Washington University in St. Louis. Over two decades at The Boeing Company, I honed my expertise in structures, materials, and integration, leading teams through some of the most complex challenges in aerospace. From developing thermoplastic composite technologies for commercial aircraft like the 787 and 777X—delivering $64M in cost savings—to managing airframe structures for the F/A-18 fighter and integrating the MQ-25 autonomous tanker, I’ve been at the forefront of innovation and execution.

One of my proudest achievements is pioneering thermoplastic composites, a game-changer in lightweight, durable materials. I hold eleven patents under my name (Charles Prebil or Charles R. Prebil) for processes and tooling concepts in this field, reflecting years of R&D leadership. My work has spanned material development, process standardization, and supplier coordination, often under the pressure of tight production schedules and rigorous DoD standards.

Leadership is at the core of what I do. I’ve managed teams of up to 75 engineers across disciplines, from design to manufacturing, fostering collaboration and driving continuous improvement. My recent roles at Boeing included Senior Manager of F/A-18 Airframe Structures and MQ-25 Air Vehicle Integration, where I tackled production issues, led root cause corrective actions, and implemented cost-saving strategies. Before that, I stood up the St. Louis Advanced Composites Lab and chaired the Thermoplastic Research Center in the Netherlands, shaping global research priorities.

Now, through chasprebil.com, I’m bringing this expertise to clients—offering composite material selection, grant writing (like my recent SBIR proposal for the Marine Corps), design reviews, and more. This blog will dive into topics like technology insertion, project management, and the future of aerospace engineering, blending practical advice with big-picture thinking.

Connect with me on LinkedIn to follow my updates, or reach out directly at chas@chasprebil.com. I’d love to hear your thoughts and explore how we can push the boundaries of engineering together. Stay tuned for my first deep-dive post!