Additive Manufacturing Engineering Manager

Additive Manufacturing Engineering Manager – Falls Church, VA

This role blends leadership, technical expertise, and operational ownership—guiding production while advancing the next generation of processes, systems, and capabilities. You'll work closely across engineering, production, and leadership teams to ensure efficient, scalable manufacturing while driving continuous improvement.

• Lead and develop a team of LFAM/FDM technicians, promoting safety, accountability, and continuous improvement.
• Own print processes and optimization, including parameters, material flow, toolpaths, and part quality.
• Troubleshoot production issues (e.g., delamination, warping, equipment faults) and implement corrective actions quickly.
• Partner with Production to streamline post‑processing and assembly workflows.
• Manage capacity planning, scheduling, and staffing in coordination with HR.
• Collaborate with Engineering and R&D on new materials, processes, and finishing methods.
• Drive automation and smart factory initiatives across the facility.
• Report to leadership on KPIs, timelines, resource use, and risks.
• Establish and maintain SOPs, ensuring quality, safety, and accurate documentation.
• Coach and develop team members through performance management and career growth planning.

• Bachelor’s degree in Mechanical Engineering, Mechatronics, Electrical Engineering, Materials Science, or related field.
• 7‑10+ years of manufacturing experience, including hands‑on additive manufacturing (LFAM and/or FDM).
• Expertise in extrusion-based printing, including toolpaths, parameter optimization, and pellet/filament material handling.
• Experience with large-format additive systems (e.g., CEAD, Caracol, Thermwood) preferred.
• Knowledge of automation, robotics, and smart factory systems (MES, ERP, IoT).
• Lean, Six Sigma, or similar experience driving yield improvement, scrap reduction, and cycle time efficiency.
• Proven ability to lead technical teams in fast-paced or startup environments.
• Strong leadership, problem-solving, and communication skills.
• Ability to work in an industrial environment and use PPE as required.

Formative 3D is an Equal Opportunity Employer. We are committed to hiring and developing the most qualified individuals based on job‑related experience, skills, and merit. All employment decisions are made without regard to race, color, religion, sex, national origin, age, disability, veteran status, or any other protected characteristic. We value a respectful, inclusive workplace where everyone has the opportunity to succeed.

Formative 3D maintains a drug‑free workplace consistent with applicable local, state, and federal laws.