Metallurgical Process Engineer

Fabri is seeking a Metallurgical Process Engineer to build and own the solidification science behind high-performance investment castings for demanding aerospace and space-industry applications. This role is for someone who reasons from the first‑principles physics of how metal freezes, feeds, and forms structure, and wants direct ownership over how critical hardware is melted, cast, solidified, inspected, and iterated on — using fundamentals rather than legacy playbooks.

We are an early‑stage investment casting startup building a fully integrated digital foundry. Our mission is to deliver precision metal castings with unparalleled speed and cost‑effectiveness. By leveraging our exclusive high‑throughput additive manufacturing process and AI‑driven design software, we can deliver castings in days, saving our customers critical time and money. We are well capitalised and backed by top‑tier investors (including RTX Ventures and Lockheed Martin) and major customers, with significant funding raised in the past year.

We’ve shipped our first customer parts and have generated significant commercial excitement in both the aerospace and industrial sectors. Fabri is located in Boston Metrowest. During this startup phase and for the foreseeable future, all employees will be on‑site and closely involved with building and operating the end‑to‑end process.

As Metallurgical Process Engineer, you will develop Fabri’s high‑temperature investment casting processes from the solidification physics up, responsible for driving parts from melt to accepted hardware with speed, control, and quality. You will predict and control how the mushy zone feeds, where shrinkage and porosity form, and how grain structure evolves, then conduct root‑cause failure analysis, eliminate casting defects, tighten process windows, and establish robust, repeatable manufacturing processes suitable for aerospace qualification.

You will also be a primary voice in designing the foundry itself. Working closely with mechanical design, automation, and other process leads, you will inform new process and equipment design and make build/buy decisions — specifying and commissioning next‑gen foundry hardware that delivers the precise thermal and process control needed to cast some of the most difficult aerospace alloys at high yield.

This is a rare chance to rethink foundry equipment and process from the ground up rather than inherit it. Reporting directly to the CTO, you will operate with high ownership and direct influence over Fabri’s technical and manufacturing direction.

• Own the solidification behavior of Fabri’s castings — relating thermal history, gradient (G), and growth rate (R) to grain size, grain growth, segregation, and microstructural outcomes, with a focus on repeatability, yield, and defect reduction.
• Predict, measure, and control shrinkage and feeding, including porous (interdendritic) flow through the mushy zone, to eliminate shrinkage porosity, microporosity, and hot tearing.
• Inform the design of new processes and equipment, rebuilding foundry hardware and process steps from first principles to achieve precise thermal and solidification control.
• Design and control solidification to manage grain structure, segregation, phase evolution, shrinkage, hot tearing, porosity, surface condition, and dimensional stability using a combination of SPC, DOE methods, and physics‑based reasoning.
• Work closely with the software team to develop in‑house thermal and solidification simulations (including gradient/growth‑rate and mushy‑zone feeding models) to guide alloy selection, gating, risering, mold design, and thermal control decisions.
• Work across the full foundry stack as needed, including patterns, shell systems, melt practice, pouring, and post‑cast processing, ensuring strong linkage between process inputs and measured solidification outcomes.
• Partner with equipment, mechanical design, and automation engineers to define requirements and build custom foundry hardware that enables new casting and solidification approaches.
• Interface directly with customers and internal stakeholders on technically deep discussions around…