Additive Manufacturing Process Engineer

We are seeking an experienced Additive Manufacturing Process Engineer to develop, optimize, validate, and support metal additive manufacturing processes, with a primary focus on LPBF/SLM. This role requires strong hands-on experience in parameter development, complex build troubleshooting, process validation, and transfer of validated processes into regular manufacturing.

Key Responsibilities

• Develop, optimize, and validate LPBF/SLM process parameters for different materials, geometries, and performance requirements.
• Provide hands-on engineering support for machine setup, build preparation, printing, troubleshooting, and complex or high-risk builds.
• Develop and qualify new metal powders, scan strategies, support strategies, and process windows.
• Lead root-cause analysis for print defects including porosity, lack of fusion, cracking, warping, delamination, recoater interference, and dimensional issues.
• Review part designs for printability, including wall thickness, internal channels, overhangs, orientation, supports, and powder removal.
• Analyze print data and test results to improve density, surface quality, dimensional accuracy, repeatability, and build success rate.
• Plan and support process validation through density testing, metallography, microscopy, dimensional inspection, surface measurement, and pressure/leak testing.
• Develop and maintain process specifications, parameter records, work instructions, validation reports, and manufacturing standards.
• Transfer validated processes from development into production and provide technical support during initial manufacturing builds.
• Support continuous improvement of machine utilization, material usage, cycle time, yield, and overall process reliability.
• Provide technical guidance and training to technicians and junior engineers.
• Support safe powder handling, equipment operation, and additive manufacturing safety requirements.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, Metallurgical Engineering, or a related field.
• 3-5+ years of relevant engineering experience, preferably in metal additive manufacturing or advanced manufacturing.
• Hands-on experience developing and modifying LPBF/SLM process parameters, not limited to operating pre-qualified parameter sets.
• Strong understanding of laser power, scan speed, hatch spacing, layer thickness, contour parameters, scan strategy, melt pool behavior, and common AM defects.
• Experience with structured troubleshooting, root-cause analysis, process validation, and technical documentation.
• Ability to independently manage process development activities and communicate technical results across engineering, quality, and manufacturing teams.

Software & Technical Skills

• Experience with AM build preparation and slicing software such as Materialise Magics, 3DXpert, Netfabb, EOSPRINT, QuantAM, or equivalent.
• Proficiency with CAD software such as Solid Works, Siemens NX, Creo, or equivalent.
• Experience with part orientation, support generation, slicing, build layout, and parameter configuration.
• Proficiency with Excel and experience with Minitab, JMP, MATLAB, Python, or equivalent data-analysis tools is preferred.
• Familiarity with metallography, microscopy, dimensional inspection, surface measurement, GD&T, and engineering drawings.
• Knowledge of DfAM, DOE, SPC, Cp/Cpk, 5-Why, Fishbone, and other structured problem-solving methods is preferred.
• Experience with complex AM geometries such as thin walls, internal channels, lattice structures, and TPMS structures is a plus.

Preferred Experience

• Experience with copper, copper alloys, aluminum, titanium, stainless steel, or other metal powder systems.
• Knowledge of downstream processes such as heat treatment, EDM, machining, blasting, and polishing.