Staff Engineer Additive Manufacturing

About Orthopaedics

Fueled by innovation at the intersection of biology and technology, we’re developing the next generation of smarter, less invasive, more personalized treatments.

Are you passionate about improving and expanding the possibilities of Orthopaedics? Ready to join a team that’s reimagining how we heal? Our Orthopaedics teams help keep more than 6 million people moving each year while delivering clinical and economic value to surgeons and healthcare systems. Our teams build solutions for joint reconstruction; trauma and craniomaxillofacial; sports, extremities, and elective foot and ankle;

spine; and robotics and digital surgery.

Your unique talents will help patients on their journey to wellness.

We are searching for a Staff Engineer, Additive Manufacturing, to support spine-focused medical device R&D through end‑to‑end titanium laser powder bed fusion (LPBF) prototyping and product development. This position is hybrid based out of our Raynham, MA office location.

• Lead end‑to‑end Additive Manufacturing process development and industrialization for complex processes and New Product Introductions (NPI), ensuring scalable, robust, and validated manufacturing processes.
• Create, modify, and optimize LPBF build files for titanium medical implants including:
  • Part orientation and nesting strategy
  • Support generation and optimization to balance surface quality and removability
  • Thermal management considerations for distortion‑sensitive implant geometries.
• Review CAD models for printability, manufacturability, and risk, providing DfAM feedback tailored to spine implants (e.g., lattice development, fixation features, anatomical surfaces).
• Maintain build documentation consistent with R&D and design control expectations.
• Be familiar with LPBF Printer Operations including
  • Machine setup, calibration, and pre‑build checks
  • Titanium powder handling, recycling, and traceability
  • Build execution, monitoring, and first‑level troubleshooting
  • Part Removal, Post‑Processing & Inspection
• Identify print anomalies relevant to implant manufacturing (distortion, support failure, surface defects).
• Support continuous improvement of AM processes, SOPs, and internal best practices for medical titanium printing.
• Perform preliminary inspection and documentation:
  • Visual inspection and defect classification
  • Basic dimensional verification
  • Identification of risks impacting downstream testing (mechanical, fatigue, coating, etc.)
• Prototype Feedback & R&D iteration.
• Provide clear, structured feedback from each build to inform:
  • Design revisions
  • Build orientation and support changes
  • Parameter and layout refinements
  • Partner closely with Spine R&D engineers, designers, and manufacturing teams to accelerate prototype learning cycles.
• Lead cost reduction and productivity initiatives (scrap/rework reduction, throughput improvements, consumables optimization) with measurable savings and sustainability impacts.
• Provide technical mentorship to engineers and technicians, champion continuous improvement culture, and support capability development across the organization.

Required Qualifications & Experience

• Bachelor’s degree or equivalent experience in Engineering (or equivalent).
• Demonstrated 4-6 years of experience in a relevant engineering role.
• Demonstrated ability in additive manufacturing/process engineering.
• 3+ years of hands‑on experience with metal additive manufacturing, preferably LPBF.
• Experience creating metal AM build files (support design, part orientation, part slicing specifications, part layout).
• Experience operating industrial LPBF printers, from build file setup to completed build.
• Strong experience in structured problem solving and root cause analysis.
• Excellent technical content skills (specifications, validation protocols, change control).
• Experience leading multi‑functional teams and influencing collaborators at multiple levels.
• Proven experience supporting NPI, scale‑up and transfer activities.

Preferred Qualifications & Experience (Nice to Haves)

• Experience specifically with titanium spinal implants or orthopedic medical devices.
• Familiarity with LPBF printing platforms, experience with 3DS…