Lead Additive Manufacturing Materials Engineer

Eaton’s AER HQ Headquarters Aerospace division is currently seeking a Lead Additive Manufacturing Materials Engineer for its Digital Design and Additive Manufacturing Center (DDAMC) in Charleston, South Carolina.

Expected annual salary range: $97,000 - $143,000. Salaries are based on candidate skills, experience, and qualifications as well as market and business considerations.

Location & Work Arrangement

• On‑site at the N. Charleston, SC facility.
• Relocation assistance available for qualified US‑resident candidates.

Additive Manufacturing (AM) is a strategic technology in the Aerospace industry. Eaton Aerospace has leveraged AM to generate significant growth, and the new Lead Materials Engineer will support the Chief Material Engineer as the AM metal expert at DDAMC, providing materials and process (M&P) support to manufacturing and engineering personnel across multiple divisions and product lines.

• Provide metallurgical technical support for laser powder bed fusion (PBF‑L) and electron beam powder bed fusion (PBF‑EB) technologies.
• Manage external M&P suppliers for raw material/feedstock, heat treatment, surface finishing, and test labs.
• Perform hands‑on characterization of powder feedstock and consolidated materials; establish lab standards, work instructions, and training.
• Maintain quality systems in the materials lab, ensure safe work practices, and drive expansion of capacity and characterization capability.
• Lead qualification of new, advanced materials/metals and manufacturing processes for high‑performance aerospace applications.
• Develop and execute overall M&P strategy aligned with AM Team business goals.

• Support and lead M&P work for new AM processes, including installation and qualification of new machines.
• Own government‑funded projects aligned with the AM M&P strategy in collaboration with the Engineering Research Laboratory.
• Apply knowledge of heat treatment processes, industrial surface finishing, material characterization/metallography, and mechanical & physical testing methods.
• Analyze interaction of metal feedstock with dynamic PBF/DED processes and the impact of rapid solidification on material properties.
• Implement AM‑related industry specifications and represent Eaton on relevant working groups.
• Advocate for improvements in product designs to ensure material compliance and prepare engineering reports summarizing results.
• Support product team reviews and provide input for AM projects across the four aerospace divisions.
• Collaborate with DDAMC Quality to define and implement monitoring and control systems for key process variables.

• Manage multiple projects and activities with a results‑driven approach.
• Communicate effectively in writing and verbally within and outside the AM Group.
• Lead root cause corrective action (RCCA) projects related to material, process, and product.
• Develop and execute new AM M&P projects identified through the Eaton Profit Planning process.
• Champion AM continuous improvement for laser and electron beam modalities.
• Participate in Rapid Improvement Events to eliminate waste and drive standardization.

• Bachelor of Science in Materials/Metallurgical Engineering or Material Science from an accredited institution.
• Minimum of 5 years experience in a production setting supporting advanced manufacturing (metal 3D printing modalities).
• Hands‑on experience with material characterization techniques (metallography, SEM, chemical analysis).
• U.S. citizenship required; all applicants must have ITAR clearance for advanced high‑priority level work.
• No immigration sponsorship will be provided or considered.

• Advanced degree (MS or Ph.D.).
• Experience with mechanical/material property testing aligned with industry specifications.
• Proficiency in statistical analysis software (e.g., Minitab) to define trends and summarize material property results.

• Expertise with aluminum and titanium AM material systems.
• Problem‑solving methodologies and risk assessment tools (Six Sigma, 8D, RCCA, PFMEA).
• Proficient in Microsoft Office.
• Experience with Minitab, FEA software.

All positions may require participation in video and in‑person interviews. All candidates are evaluated based on job‑related competencies. Employment decisions are based on job‑related reasons and protected under the Equal Employment Opportunity laws. Qualified applicants with arrest or conviction history will be considered equally, in accordance with applicable local ordinances and fair‑chance laws. Requests for reasonable accommodations may be made by contacting Eaton at 1‑800‑836‑6345.