PhD Graduate - Postdoctoral Researcher - In-Situ Sensing Additive Manufacturing

Overview

Position: 2026 PhD Graduate - Postdoctoral Researcher - In-Situ Sensing for Additive Manufacturing

Employer:

Johns Hopkins Applied Physics Laboratory

Base pay range: $85,300.00/yr - $/yr

• Collaborate with APL scientists, engineers, and technicians to develop novel closed-loop sensing and control solutions tailored for additive manufacturing.
• Perform pioneering research in materials and process characterization by fusing in-situ sensing modalities to optimize microstructure and density in metal additive manufacturing.
• Utilize AI and ML algorithms to extract insights from multi-modal sensor data, improve real-time process monitoring, and drive automated control systems.
• Design, implement, and validate adaptive control algorithms that leverage sensor feedback to dynamically adjust processing parameters in real time.
• Engage with a multidisciplinary team focused on materials discovery, novel fabrication techniques, multiscale modeling, processing insights, advanced testing, and qualification science.
• Present technical findings to internal and external audiences, effectively communicating complex concepts to team members, task leads, and project leadership.
• Contribute to the design, fabrication, and characterization of additively manufactured operational prototypes that demonstrate intelligent process control.

• Possess a Ph.D. in Mechanical Engineering, Electrical Engineering, Materials Science, Data Science, or a related field.
• Have strong written and oral communication skills, with the ability to engage wide-ranging audiences and adapt to different communication styles.
• Are adaptable, enthusiastic about new challenges, and have a passion for learning with a collaborative mindset open to sharing and receiving feedback.
• Have experience solving multidisciplinary research challenges related to qualified hardware and additive manufacturing.
• Demonstrate a fundamental understanding of additive manufacturing, including process defects, microstructure evolution, and thermodynamic solidification.
• Have a demonstrated track record of authoring research proposals and publishing high-impact journal papers.
• Are willing and able to work in a laboratory setting and travel for field testing, sponsor meetings, conferences, and technical presentations.
• Are able to obtain a Secret-level security clearance to start with APL and then up to Top Secret clearance. If selected, you will be subject to a government security clearance investigation, and must meet the eligibility requirements for access to classified information, including U.S. citizenship.

• Have experience fielding additively manufactured components.
• Demonstrate the ability to fuse 2D and 3D data, including in-situ and post-manufacturing data, into a 3D format for advanced processing and visualization.
• Have experience applying AI/ML techniques to complex datasets, including deep learning models for defect detection, anomaly detection, and predictive modeling of additive manufacturing processes.
• Have hands-on expertise in developing novel in-situ monitoring methods for additive manufacturing, including custom sensor development to improve signal-to-noise ratios and spatial registration.
• Have experience with digital twin technology and reinforcement learning for real-time optimization of manufacturing parameters.
• Have experience working with voxel-based data and mapping physical quantifications across multiple sensing platforms.
• Possosess strong scientific programming skills using tools such as MATLAB or Python, with experience in machine learning frameworks such as Tensor Flow, PyTorch, or Scikit-Learn.

We are seeking a postdoctoral fellow with proven expertise in in-situ sensing, AI, and data fusion for additive (or other advanced) manufacturing processes to drive innovation in real-time monitoring and closed-loop control of advanced manufacturing systems. In this role, you will collaborate with a multi-disciplinary team to demonstrate multi-modal in-situ sensing and real-time adaptive control in advanced manufacturing environments.

At APL, we encourage our team members to generate and lead their own research initiatives while also publishing their findings in high-impact venues. We are a collaborative, risk-taking, and innovative research team dedicated to solving complex technical challenges with national impact. If you are excited about the opportunity to shape the future of additive manufacturing through sensing, AI, and adaptive control systems, we would love to hear from you!

Why Work at APL? The Johns Hopkins University Applied Physics Laboratory (APL) brings world-class expertise to our nation’s most critical defense, security, space and science challenges. We offer a vibrant, welcoming atmosphere where you can bring your authentic self to work, continue to grow, and build strong connections with inspiring teammates. All qualified applicants will receive consideration for employment without regard to race, creed, color,…