Senior Process Engineer, Additive Manufacturing

We’re looking for an industry-experienced, hands-on senior engineer with direct metal additive manufacturing experience - someone who has qualified materials and processes, troubleshot builds, analyzed failures and test results, and turned technical findings into reliable production solutions.

You’ll own our metallurgical test lab, lead material and process qualifications across multiple alloy systems, and work directly with AM equipment, materials, engineering, quality, and production to solve technical challenges and establish robust manufacturing processes.

• Build and operate our metallurgical test lab.
  Take our internal test lab from concept to day-to-day operation. You’ll help select and qualify equipment, establish test methods and procedures, develop calibration and maintenance requirements, and train others to use the equipment correctly. Capabilities will include particle size distribution, porosity characterization, mechanical testing, and microstructural analysis.

• Lead hands-on material and process qualification.
  Develop and execute qualifications for stainless steel, nickel, titanium, aluminum, and other alloy systems. You’ll work directly with AM processes and equipment to establish parameters, run trials, evaluate results, and qualify processes to customer and industry requirements, including AMS, ASTM, and SAE standards.

• Troubleshoot real manufacturing problems.
  When a build, material, or test result doesn’t meet expectations, you’ll help determine why. You’ll use metallurgical analysis, process data, structured experimentation, and hands-on investigation to identify root causes and implement practical corrective actions.

• Own qualification from planning through execution.
  Lead IQ/OQ/PQ activities, DOE-based studies, process-window development, validation testing, documentation, and technical reporting. You’ll manage multiple qualification efforts and be accountable for driving them through completion.

• Partner directly with manufacturing.
  Work closely with engineering, quality, and production to translate metallurgical requirements into processes that work on the shop floor. You’ll help establish build and validation documentation in Pro Shop ERP and develop practical training for the team.

• Advance our AM capabilities.
  Identify better ways to qualify materials, validate processes, evaluate results, and solve emerging technical challenges as Rennscot’s additive manufacturing business grows.

We are open to a range of educational backgrounds — what matters most is what you have done and the impact you have made.

• 12+ years (H.S. Diploma) | 10+ years (A.A.) | 5+ years (Bachelor's) | 3+ years (Master's) | Ph.D.

• A bachelor's or master’s in metallurgical engineering, materials science, or a closely related field is preferred.

• Direct, hands-on experience with metal additive manufacturing processes such as laser powder bed fusion, DED, or binder jetting

• Experience developing, qualifying, or improving AM materials and manufacturing processes in an industrial environment

• Practical experience troubleshooting AM builds, material issues, defects, or process variation

• Hands-on metallurgical testing experience, including microstructural analysis, porosity, mechanical testing, and/or powder characterization

• Experience working with stainless steel, nickel, titanium, aluminum, or similar alloy systems

• Experience executing process or equipment qualification, including IQ/OQ/PQ or comparable validation methodologies

• Working knowledge of AMS, ASTM, SAE, customer specifications, or similar manufacturing standards

• Experience using DOE, statistical analysis, and process data to make manufacturing decisions

• Ability to translate metallurgical principles — including…