AM Design Engineer

GM Performance Power Units
- Concord, NC AM Design Engineer
- Onsite Job Summary

The AM Design Engineer will serve as a rotational member of product design teams, embedding directly into projects to apply AM design principles and provide feedback to the core AM Design group. This role focuses on developing optimized geometries for laser powder bed fusion using 3DXpert and NX, while also supporting prototyping, fixtures, and tooling through FDM systems. A key part of the role is creating and refining test geometries in collaboration with the AM Materials and AM Process teams to accelerate parameter development and process optimization.

Success in this role means delivering manufacturable, cost-effective designs that balance design freedom with process constraints, while building foundational expertise in AM design.

• Apply design-for-additive-manufacturing (DfAM) rules and guidelines to create optimized LPBF parts.
• Collaborate with product design teams on part orientation, support strategies, and manufacturability reviews.
• Develop and iterate test geometries to support AM Materials and AM Process teams in parameter, simulation, and process optimization.
• Support rapid prototyping efforts using in-house and external AM equipment, including FDM for fixtures, tooling, and prototypes.
• Assist in training and mentoring junior designers on AM design practices.
• Document lessons learned and contribute to the continuous improvement of AM design standards and best practices.
• Collaborate with downstream manufacturing stakeholders to ensure efficient and achievable manufacturing plans.
• Become a technical resource and mentor for cross functional teams incorporating AM into their manufacturing workflow.

• Bachelor’s degree in Mechanical Engineering or a related field.
• 1–3 years of professional experience in design engineering; prior LPBF AM exposure preferred.
• Proficiency in Siemens NX (preferred) or similar 3D CAD software is required.
• Familiarity with AM-specific software such as 3DXpert, nTop, or Materialise is preferred.
• Understanding of DfAM principles, particularly for LPBF.
• Working knowledge of 3D GD&T and application to downstream processes of the Additive component such as Machining, Welding, and Assembly
• Strong problem-solving skills, attention to detail, and eagerness to learn in a fast-paced environment.
• Ability to solve complex problems using innovative solutions while having the agility to adapt to evolving part designs and requirements.
• Ability to collaborate across design, materials, and process teams.
• Strong functional mechanical knowledge, establishing a working familiarity with product team’s design intent and goals in order to best utilize and “sell” the advantages of AM to develop the highest performing and efficient component.
• Working knowledge of LPBF equipment operation, setup, and material handling is preferred.

• Design quality and manufacturability: percentage of parts meeting specification with minimal design cycles and efficient post processing.
• Iteration speed: ability to deliver optimized designs and test geometries within project timelines.
• Cross-team impact: measurable contributions to Materials and Process teams through effective test geometry design.
• Knowledge transfer: effectiveness in capturing and sharing design insights with the core AM Design team and product design teams.

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