Cold Spray Additive Manufacturing Engineer

Description

Leidos Dynetics' Advanced Materials Department is seeking a motivated, detail-oriented engineer to join our team as a Cold Spray Additive Manufacturing Engineer
. This position is ideal for a recent graduate who is passionate about advanced manufacturing, materials engineering, and the development of next‑generation defense and aerospace technologies.

• Support operation, setup, and maintenance of cold spray additive manufacturing equipment and associated systems.
• Assist in the design and fabrication of components using cold spray and other metal additive manufacturing technologies.
• Apply Design for Additive Manufacturing (DfAM) principles to support component design and process planning.
• Develop build plans, work instructions, and process documentation for additive manufacturing activities.
• Support material and process development efforts through experimental testing and data collection.
• Conduct basic engineering analyses related to additive manufacturing feasibility, cost, manufacturability, and performance.
• Assist with metallographic preparation, material characterization, and mechanical test specimen fabrication.
• Analyze and document process data, test results, and inspection findings.
• Collaborate with multidisciplinary teams including design, manufacturing, quality, and materials engineers.
• Support laboratory operations, equipment troubleshooting, and continuous process improvement activities.
• Contribute to technical reports, presentations, customer deliverables, and research proposals.
• Maintain compliance with safety procedures and laboratory best practices.

• Bachelor's degree in Mechanical Engineering, Materials Science and Engineering, Manufacturing Engineering, Aerospace Engineering, or a related STEM discipline from an ABET-accredited university.
• Minimum cumulative GPA of 3.2.
• Resident of North Alabama or willingness to relocate to Huntsville, AL.
• Familiarity with additive manufacturing concepts through coursework, laboratory experience, internships, undergraduate research, or personal projects.
• Familiarity with the operation of cold spray additive manufacturing equipment.
• Familiarity with operational safety procedures and practices for metal additive manufacturing.
• Understanding of and ability to apply Design for Additive Manufacturing (DfAM) principles.
• Ability to interpret engineering drawings and technical documentation.
• Demonstrated hands‑on laboratory, manufacturing, machining, fabrication, or research experience.
• Strong problem‑solving, communication, and teamwork skills.
• Ability to obtain and maintain a U.S. Government security clearance.
• U.S. Citizenship required.

• Internship, co‑op, undergraduate research, or project experience involving metal additive manufacturing.
• Experience operating Cold Spray Additive Manufacturing, Directed Energy Deposition (DED), Laser Powder Bed Fusion (LPBF), Wire Arc Additive Manufacturing (WAAM), or related equipment.
• Experience with additive manufacturing software such as Materialise Magics, 3DXpert, EOSPrint, Netfabb, or similar tools.
• Experience with CAD software such as Solid Works, Creo, NX, or similar design tools.
• Experience operating laboratory or manufacturing equipment.
• Coursework or laboratory experience involving metallurgy, materials characterization, or manufacturing processes.
• Experience with metallographic specimen preparation and optical or electron microscopy.
• Exposure to mechanical testing methods including tensile, fatigue, creep, or hardness testing.
• Familiarity with high‑performance metallic materials including nickel‑based alloys, titanium alloys, stainless steels, aluminum alloys, or refractory materials.
• Experience supporting research projects, technical reports, conference papers, or engineering presentations.
• Knowledge of manufacturing safety practices and laboratory procedures.
• Demonstrated leadership through engineering organizations, design teams, student projects, or extracurricular activities.

Pay Range: $57,850.00 – $. The Leidos pay range for this job level is a general guideline only and not a guarantee of compensation or salary. Additional factors…