Additive Manufacturing Engineer

Firehawk Aerospace is a leading propulsion-focused aerospace and defense company located in Addison, TX. Our innovative approach empowers us to design and manufacture cutting‑edge solid and hybrid rocket motors and engines. We aim to push the boundaries of propulsion technology to serve both commercial and defense sectors.

This position will be full‑time, located at our Addison, TX facilities with occasional travel potentially required (approximately 30%).

Firehawk Aerospace is seeking an Additive Manufacturing Engineer to support the development and production of munitions. The position will report directly to the Design Manager and will support all areas of the organization (Design, Testing, Manufacturing). The ideal candidate should be an effective communicator who works well in teams and with limited supervision. They should possess broad knowledge and experience with 3D printing systems and processes, particularly with polymers.

• Design and develop additively manufactured parts using state‑of‑the‑art, large format 3D printers for solid/hybrid rocket systems
• Interact with additive manufacturing equipment suppliers to implement hardware and software capabilities to enhance equipment capability and efficiency
• Design solid models of prototypes, jigs, fixtures and tools to be used for rapid design iteration and/or production/assembly support
• Document processing and testing conditions for all experiments and interpret results and prepare technical reports
• Develop additive manufacturing equipment standard operating procedures and best practices
• Identify limitations or inefficiencies in the current printing processes and implement solutions
• Drive continuous improvement in design, simulation, production, and post‑processing technologies for additive manufacturing
• Operate and maintain a variety of 3D printing systems, support/test equipment, and post‑processing equipment/tools
• Make project decisions based on technical merit, cost, and schedule metrics
• Collaborate with other engineers and project managers to meet project goals

• Bachelor’s degree in aerospace engineering, mechanical engineering, chemical engineering, or related field
• 5+ years of professional experience in polymer additive manufacturing
• Experience utilizing slicing software (Cura, Simplify3D, etc.) to generate machine toolpaths
• Knowledge of thermoplastic additive manufacturing process parameters (print speed, material flow rate, layer height, bead width, etc.) and how changes affect the produced parts
• Experience with CREO (preferred), or other CAD software
• Capability to manage project efforts and solve complex problems
• Strong work ethic and ability to thrive in a fast‑paced R&D environment
• Self‑motivated with strong organizational, written, and oral communication skills
• Focus on safety, reliability, innovation, efficiency, and teamwork
• Foster trust and maintain positive, professional relationships
• Proficiency with Microsoft Office products (Word, Excel, PowerPoint, One Note, etc.)
• U.S. Citizenship and ability to obtain a security clearance
• Ability to lift 25 pounds and work on test/flight hardware
• Must be willing to travel as required

• Master’s degree in aerospace engineering, mechanical engineering, chemical engineering, or related field
• 10+ years of professional experience in additive manufacturing
• Experience operating large format pellet extrusion additive manufacturing systems
• Experience generating customized G‑code/toolpaths to optimize part production
• Experience with mechanical testing of additively manufactured samples
• Experience with in‑situ process monitoring techniques for polymer additive manufacturing
• Experience with missile and/or solid rocket motor design
• 5+ years of experience with CREO (preferred), or other CAD software
• Experience with PLM software (Windchill preferred)
• Proficient with GD&T, tolerance analysis, design for manufacturability
• General understanding of manufacturing processes (welding, machining, heat treating, etc.)
• General understanding of structural analysis and failure modes of mechanical systems
• Active or previous security clearance

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