Mechanical Engineer - SPP and Advanced Manufacturing

Job Title

Pacific Northwest National Laboratory (PNNL) Applied Materials and Manufacturing group is seeking an outstanding researcher/engineer with expertise in solid-phase processing (SPP) to join a world-class, interdisciplinary research program advancing next-generation metals manufacturing for a broad range of energy, defense, and industrial applications.

This is a highly hands-on position supporting the development of advanced manufacturing technologies including friction stir welding, friction stir processing, friction stir consolidation, shear-assisted processing and extrusion (ShAPE), friction extrusion, and cold spray. The successful candidate will collaborate with materials scientists, mechanical engineers, manufacturing researchers, and industrial partners to develop innovative processing solutions while advancing the understanding of processing-structure-property relationships across a variety of metallic materials and manufacturing platforms.

The successful candidate will:

• Work directly with advanced solid-phase processing equipment, tooling, robotics, automation systems, and materials characterization techniques.
• Design, develop, and optimize manufacturing equipment, tooling, fixtures, and processing approaches for research and industrial applications.
• Support design-build-test activities, including adaptation of tooling and systems for robotic manufacturing platforms and prototype equipment.
• Investigate relationships between processing conditions, microstructure evolution, and material performance through experimentation and characterization.
• Develop material- and application-specific processing parameters, workflows, and manufacturing protocols.
• Apply principles of physical metallurgy and materials science to integrate machine development with process optimization across multiple manufacturing technologies.
• Coordinate fabrication activities with machinists, engineers, and technical staff.
• Develop testing strategies and recommendations consistent with ASTM and ISO standards.
• Prepare technical reports, peer-reviewed publications, conference presentations, and sponsor deliverables.
• Contribute to proposal development, strategic research planning, and new program development.
• Lead small engineering or research projects while delivering high-quality results on schedule and within budget.

The ideal candidate will possess:

• Strong technical problem-solving, analytical, and troubleshooting skills.
• Experience with machine, tooling, fixture, and manufacturing equipment design using Solid Works or equivalent CAD software.
• Familiarity with finite element analysis (FEA), thermal modeling, computational materials engineering, or process simulation tools.
• Knowledge of physical metallurgy, materials processing, deformation mechanisms, and processing-structure-property relationships.
• Experience with advanced materials characterization and interpretation of microstructural and mechanical property data.
• Experience with industrial robotics, automation, advanced manufacturing systems, and process controls.
• Excellent written and verbal communication skills with strong attention to detail.
• Ability to develop innovative concepts and coordinate all aspects of the design-build-test process.
• Familiarity with clean-sheet engineering and manufacturing system design is desirable.

The researcher/engineer will:

• Build a nationally recognized technical reputation through innovative research and engineering.
• Develop creative technical solutions to complex manufacturing and materials challenges.
• Establish collaborative technical relationships across multidisciplinary teams within PNNL and with external partners.
• Mentor students, interns, and early-career researchers.
• Independently execute research assignments while effectively balancing multiple priorities.
• Present research findings at national and international technical conferences.
• Lead portions of proposals, technical reports, journal publications, and sponsor deliverables.
• Maintain the highest standards of quality, safety, security, and scientific integrity.

Minimum Qualifications:

• BS/BA and at least 2 years of relevant Mechanical Engineering experience
  -OR-
• MS/MA
  -OR-
• PhD
• Demonstrated expertise in one or more solid-phase processing technologies, such as friction stir welding, friction stir processing, friction stir consolidation, shear-assisted processing and extrusion (ShAPE), friction extrusion, hot extrusion, equal-channel angular pressing/extrusion (ECAP/ECAE), cold spray, or related severe plastic deformation processes.

Preferred Qualifications:

• Hands-on experience operating, troubleshooting, and optimizing advanced manufacturing equipment for research or industrial applications.
• Experience designing or modifying manufacturing equipment, tooling, fixtures, robotic end-effectors, or process hardware using Solid Works or equivalent CAD software.
• Strong knowledge of physical and mechanical metallurgy, including microstructural…