Senior Engineer, Additive Manufacturing at Beehive Industries Knoxville, TN

Senior Engineer, Additive Manufacturing – Beehive Industries, Knoxville, TN.

Beehive Industries is dedicated to powering American defense by revolutionizing the design, development, and delivery of jet propulsion systems to support the warfighter. Through the integration of additive manufacturing, the company aims to meet the growing and urgent needs for unmanned aerial defense by dramatically improving a jet engine’s speed to market, fuel efficiency, and cost. Founded in 2020, Beehive Industries is headquartered in Englewood, Colorado, with additional facilities in Knoxville, Tennessee, Loveland Ohio, and Mount Vernon, Ohio.

The company is committed to growing and advancing the defense industrial base while manufacturing exclusively in the USA.

The Senior Additive Manufacturing Engineer is a key part of a team involved in the development and optimization of additive parts and components for the Aerospace and Defense industries. This role specifically focuses on leading process development from build preparation and printing through post-processing, including heat treatment, machining, and quality assurance for new additive applications.

• Act as a subject matter expert (SME) on process development for metal AM technologies, industry best practices, and optimal process solutions to support our AM requirements
• Develop and optimize the entire suite of AM processes for metal printer recipes, post‑machining, heat treatments, surface finishes, and NDT
• Enjoy working in a fast‑paced environment and be comfortable working through complex and collaborative problem‑solving
• Work with design engineers on DFAM for the adoption and transition of printing modalities
• Support and drive learning from CAD data through simulation, design compensation, optimization, support generation, build prep, and production guidelines and documentation
• Provide feedback to design engineers and production floor to continuously improve the AM part production process
• Perform analysis, characterization, simulation, testing, and verification of AM hardware as well as AM material properties and analyze results from downstream fabrication and testing operations to inform process improvements
• Generate and release additive process specifications to control product quality and establish build qualification and product acceptance criteria
• Work closely with stakeholders in achieving and maintaining aerospace and defense driven AM process and facility qualifications and certifications
• Advise on materials, machines and process parameters to build parts that meet specifications
• Actively and closely work with quality engineers to identify and qualify vendors and suppliers for materials and post‑process services
• Travel approximately 10% across Beehive’s manufacturing sites to manage the technology development programs

• Bachelor’s degree in Materials Engineering, Mechanical Engineering, or related discipline with typically a minimum of 5 years of related experience, or a master’s with 3 years of experience
• Demonstrated expertise in additive manufacturing process development with focus on L‑PBF
• Hands‑on operation of additive manufacturing L‑PBF machines, process parameter development and direct experience building parts on AM machines such as the EOS M400 and similar
• Process knowledge for metal AM to make successful builds in Nickel, Aluminum, and Titanium alloys
• Proficient in using software focused on design for AM, build‑file preparation, process simulation, and in‑process monitoring
• Knowledge and application of post‑printing processes for metal 3D‑printed parts, such as drying, sintering, heat‑treatment schedules, surface finishing, and powder removal
• Experience working in an AS9100 and ISO
  9000 environment
• Knowledge of AM and aerospace industry standards, including ASTM, ISO, AMS, SAE, etc
• Knowledge of geometric dimensioning and tolerancing (GD&T)
• Ability to obtain and maintain a U.S. government‑issued security clearance is required; U.S. citizenship is required

• Served 5+ years in an AM shop environment, specializing in 3D printing operation and maintenance of AM machines, especially L‑PBF for aerospace and…