Senior Materials Engineer
Listed on 2026-05-24
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Engineering
Materials Engineer, Manufacturing Engineer, Quality Engineering, Process Engineer
About Us
Founded in 2015 to develop the world’s first industrially scalable laser metal additive manufacturing solution, Vulcan Forms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting-edge technology with a foundation of proven industrial craftsmanship.
Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.
As the Staff Materials Processing Engineer at Vulcan Forms Inc., you will serve as the principal technical authority responsible for developing, optimizing, and qualifying all post-build processing methodologies for advanced, additively manufactured metal components. You will lead the technical strategy for post-print operations—including industrial heat treatment, hot isostatic pressing (HIP), chemical surface finishing, and advanced mechanical testing—to ensure that laser powder bed fusion (LPBF) components meet strict aerospace, defense, and medical industry requirements.
Operating as a high-level subject matter expert (SME), you will bridge the gap between materials science R&D and high-volume production, authoring foundational company-wide material specifications, governing metallurgical laboratory practices, and delivering technical certification frameworks for our most strategic global customers.
- Architect and qualify scalable, production-ready thermal and surface post-processing parameters (vacuum heat-treating, HIP, chemical/mechanical surface improvements) for complex material systems, including Titanium alloys, Nickel-based Superalloys, and Stainless Steels.
- Author, approve, and maintain company-wide material and process specifications, establishing the definitive inspection and qualification protocols required for flight, defense, and medical-grade hardware.
- Govern metallurgical laboratory operations and testing methodologies, driving advanced destructive and non-destructive testing (NDT) campaigns to substantiate component integrity and microstructural compliance.
- Lead high-level microstructural characterization and failure analysis investigations utilizing advanced optical microscopy, Scanning Electron Microscopy (SEM), and Energy Dispersive X-ray Spectroscopy (EDS) to solve complex manufacturing blocks.
- Design and oversee comprehensive mechanical testing campaigns (including tension, fracture toughness, and advanced fatigue testing like Axial and Rotating Beam fatigue) and implement robust statistical data analysis to validate part performance.
- Serve as the primary technical interface for tier-one customers and regulatory auditors; compile technical reports, deliver engineering presentations, and own the final certification documentation.
- Provide technical mentorship and coaching to junior materials engineers and lab technicians, raising the organization's collective technical capability while championing a culture of strict safety compliance (handling acids, bases, and heavy equipment).
- 8+ years of progressive engineering experience in an aerospace, defense, power generation, or medical implant materials laboratory environment.
- Bachelor’s degree in Materials Science, Metallurgical Engineering, or a related discipline. Master’s or Ph.D. is highly preferred.
- Expert-level understanding of physical metallurgy, phase transformations, and post-processing reactions specifically tailored to Laser Powder Bed Fusion (LPBF) or related metal additive manufacturing technologies.
- Proven track record of developing and scaling industrial-scale thermal profiles utilizing vacuum…
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