AM Materials & Process; M&P) Engineer

GM Performance Power Units is seeking a multidisciplinary Additive Manufacturing Materials & Process Engineer to drive the development, qualification, and optimization of metal additive manufacturing workflows. This integrated role unites material science and process engineering - ensuring every stage, from powder feedstock to heat-treated component, is engineered for performance, repeatability, and speed. The engineer will be responsible for defining parameters, validating materials, analyzing data, and leading data-driven continuous improvement activities that deliver championship-caliber parts.

• Develop and optimize part routings & AM build files to enable efficient and repeatable AM manufacturing workflows through internal ERP/MES system
• Define, validate & optimize LBPF process & material specifications to drive cost effective yet consistent & repeatable AM processes.
• Design and execute lean DOEs to optimize laser processing parameters and heat treatments, prioritizing speed, cost efficiency, and actionable outcomes that maximize performance.
• Develop and execute witness coupon and feedstock test plans that validate both material performance and process stability.
• Perform robust DOE’s to assess the effect of key process variables on both powder lifecycle, HT and material characteristics.
• Oversee powder lifecycle management, sampling, reuse strategy & contamination control plan
• Partner with team members to define both machine & part qualification plans to characterize material of unique part geometries to ensure reliability and repeatability.
• Maintain statistical process control (SPC) and data analysis to track performance trends and drive continuous improvement across the full value chain (Machine, Powder & Material)
• Develop, maintain & integrate IoT-based monitoring, sensor feedback, and MES data collection into a centralized database.
• Support PFMEA creation, control plan development, and QMS documentation.
• Partner closely with AM Design, AM Operations, and Quality Engineering to ensure manufacturability, repeatability, and throughput.

• Bachelor’s or Master’s degree in Materials Science, Mechanical, or Manufacturing Engineering.
• 2+ years of experience in metal additive manufacturing (LPBF preferred).
• Strong knowledge of powder metallurgy, heat treatment, and AM process development.
• Proficiency in DOE, SPC, and data analytics tools (Minitab, JMP, or Python).
• Familiarity with AS9100 / Nadcap, PFMEA, and QMS documentation.
• Skilled in AM software such as 3DXpert, Dyndrite, or Materialise Magics.

• Parameter and material qualification lead-time reduction.
• Enabling design freedom without compromising part quality or process cost.
• First-pass yield, density, and mechanical property conformance.
• Scrap and rework cost reduction.
• Stable powder reuse and lot traceability performance.