Additive Manufacturing & Metallurgical Lead

Job Overview

Would you like to be part of a highly technical, collaborative, and multifaceted team with expertise that spans the disciplines of aerospace, mechanical engineering, and physics? Do you enjoy solving challenges related to materials science and its applications in missile systems? Do you have a passion for finding solutions to current and emerging materials challenges for the Department of Defense (DoD)?

If so, we’re looking for someone like you to join our Materials Engineering section. Our mission focuses on innovation, integration, and characterization of materials for missile defense. We operate at the intersection of material innovation, modeling, damage mitigation, and energetics. Working with state‑of‑the‑art facilities and subject‑matter experts, you will help advance advanced propulsion, next‑generation interceptors, and structural integrity for high‑performance projectiles.

• Design and qualify proprietary alloys for metal 3‑D printing that provide enhanced structural integrity at temperatures exceeding current industry standards.
• Apply additive manufacturing to create complex, high‑efficiency rocket nozzles and engine components that enable greater interceptor speed and maneuverability.
• Develop reactive structural materials and metallized fuels that integrate structural support with enhanced energetic performance.
• Use advanced characterization techniques to predict damage growth mechanisms from EMP, kinetic impact, and thermal stress in printed components.
• Oversee the fabrication of resilient defense infrastructure components, utilizing AM to reduce maintenance cycles and improve system‑level reliability.
• Develop and optimize metal powders and feedstock for AM/DED processes, focusing on improving creep resistance and thermal stability.
• Lead efforts in Directed Energy Deposition to create complex, multi‑functional geometries for aerospace propulsion and structural systems.
• Evaluate material performance under combined loads, including kinetic, thermal, and chemical stressors.
• Analyze damage growth mechanisms in printed parts, focusing on high‑velocity impact and environmental degradation (e.g., oxidation).
• Contribute to the development of reactive structural materials to enhance the kinematic capabilities and lethality of missile/projectile systems.

• Possess a BS in Metallurgical Engineering, Materials Science and Engineering, or Materials Engineering, with a minimum of five years of related experience.
• Have demonstrated hands‑on expertise with metal additive manufacturing and alloy design platforms.
• Have a strong background in physical metallurgy and hands‑on expertise with DED and powder‑bed fusion platforms.
• Can correlate micro‑structural evolution during the AM process with macro‑scale performance in extreme aerospace environments.
• Have excellent communication skills to interface with sponsors, contractors, and Program Managers.
• Can obtain an interim Secret‑level security clearance by your start date and ultimately obtain a Secret‑level clearance. Eligibility includes U.S. citizenship.

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 celebrate diverse perspectives and encourage creativity and bold ideas. Our employees enjoy generous benefits, including education assistance, excellent retirement contributions, and a healthy work/life balance. APL is located in the Baltimore‑Washington metro area.

All qualified applicants will receive consideration for employment without regard to race, creed, color, religion, sex, gender identity or expression, sexual orientation, national origin, age, physical or mental disability, genetic information, veteran status, occupation, marital or familial status, political opinion, personal appearance, or any other characteristic protected by applicable law. APL is committed to providing reasonable accommodation to individuals of all abilities.

If you require a reasonable accommodation to participate in any part of the hiring process, please contact Accommodations.

Minimum Rate: $100,000 Annually
Maximum Rate: $245,000 Annually