Mechanical Research and Development Engineer

Overview

We are searching for a Mechanical Research and Development Engineer to join the Expeditionary Manufacturing and Repair Department at the Applied Research Laboratory (ARL) at Penn State. The role supports research and development of new materials, innovative material system designs, and novel fabrication and testing methods across ceramics, metallics, and ceramic/metal matrix composites.

• Provide input to and assist with sample production and Cold Spray process support equipment setup, design and assembly.
• Perform fabrication, machining, characterization, and mechanical testing of materials in support of projects.
• Meet with faculty and staff engineers to define task scope, schedule constraints, and communicate progress.
• Conduct daily specimen and coupon fabrication operations and fabricate facility and test equipment.
• Document process parameters and processes.
• Operate and maintain Cold Spray, Cold Spray Additive Manufacturing, and Wire Arc Direct Energy Deposition systems including stationary and portable robotics.
• Inspect, test, and calibrate equipment as directed.
• Perform facility maintenance and repair of capital and test equipment.
• Assist senior technical/engineering staff in gathering, compiling, and archiving test data.
• Develop documentation of task procedures and process evaluation.

• Bachelor's Degree in Engineering, Science, or Engineering Technology Discipline and 4+ years related experience.
• Strong foundation in machining, including CNC and Manual Machining.
• Past success using different materials and processes, repair and maintenance technology, robotics, scheduling, logistics, and program/job planning.
• Understanding of mechanical and electrical systems and industrial work environments.
• Laboratory testing proficiency and ability to follow test procedures and standards.
• Welding, sheet metal fabrication, electrical wiring (AC and DC).
• Experience interpreting and applying geometric dimensioning and tolerancing (GD&T).
• General equipment maintenance and routine preventative maintenance.
• Machine shop/lab safety practices.
• Strong communication and organizational skills in a technical environment.
• Problem‑solving using proper steps to define and formulate solutions.
• Microsoft Office proficiency.

• Additive manufacturing and/or Cold Spray.
• Robotic systems and programming.
• Understanding of Navy shipyard operations and materials, including Cold Spray, welding, electroplating, etc.
• Knowledge of CAD/CAM and mechanical design and drafting.
• Current eligibility for access to classified information at the Secret level or higher, subject to background investigation.

The position will be fully on‑site in State College, PA. Periodic travel to remote locations may be required.

Bachelor's Degree in Engineering or Science and 2+ years of relevant experience.

Employees must be eligible to obtain a government security clearance, participate in ARL drug testing, and comply with monitoring requirements. U.S. citizenship is required.

Salary range: $81,312.00 – $ (includes all possible grades). Penn State provides comprehensive medical, dental, vision, retirement plans, paid time off, and a 75% tuition discount for employees and eligible family members.

Penn State is an equal opportunity employer and is committed to providing employment opportunities to all qualified applicants without regard to race, color, religion, age, sex, sexual orientation, gender identity, national origin, disability, or protected veteran status.