Additive Manufacturing Engineer
About the role
Leidos’ Defense Systems is seeking an Additive Manufacturing Engineer to join our team supporting the Advanced Materials Department. The Advanced Materials Department is a multi-disciplinary team providing materials engineering expertise for every phase of a program.
Responsibilities
- Design for additive manufacturing (DfAM)
- Developing plans and layouts for additive manufacturing equipment and capabilities
- Contributing to multiple program teams as the resident additive manufacturing expert across multiple metal additive technologies
- Performing additive manufacturing analyses including cost, feasibility, deformation, expected material/component mechanical and thermal properties
Requirements
- Resident of North Alabama or willing to relocate to work on-site in Huntsville, AL.
- Hands-on experience with metal additive manufacturing engineering.
- Basic understanding of design for additive manufacturing (DfAM), especially with Powder Bed Fusion, DED, and/or Cold Spray.
- Experience with and basic understanding of design for additive manufacturing (DfAM), especially with Powder Bed Fusion, DED, and/or Cold Spray.
- Experience with metal additive manufacturing support structure design.
- Experience setting up metal builds with software like Materialise Magics, Oqton 3DXpert, EOSPrint, etc.
- Ability to support hardware systems including setup, operation, and troubleshooting of AM equipment.
- Familiar with high strength/temperature metal alloys (nickels, HEAs, refractories, etc.).
- Bachelor’s degree with a minimum 3.2 GPA in mechanical engineering, materials science, manufacturing engineering, or a related field from an ABET accredited university.
- 4+ years experience in metal additive manufacturing, or MS with 2+ years experience, or PhD with 1+ years experience.
Preferred Qualifications
- Hands-on experience with the following metal additive manufacturing processes: Laser Powder Bed Fusion (LPBF), Cold Spray Additive Manufacturing, Directed Energy Deposition (DED), and Wire Arc Additive Manufacturing (WAAM).
- Experience with build parameter development, process development/optimization, and qualification.
- Familiarity with post-processing methods including heat treatment, machining, and surface finishing.
- Experience with simulation tools for additive manufacturing (thermal, distortion, support optimization).
- Exposure to in-situ monitoring systems or sensor integration in AM platforms.
- Programming or scripting experience (Python, MATLAB, or similar) for data analysis or workflow automation.
- Experience with mechanical testing, including monotonic, fatigue, creep, etc.
- Experience with metallurgical specimen preparation and inspection.
- Experience in communicating with external vendors or in contract manufacturing.
- Experience obtaining quotes for work and equipment.
- Experience writing proposals.
- Design experience on Solidsworks, Creo, or other CAD systems.
- Experience troubleshooting and maintaining complex AM equipment, including laser optics, process monitoring.
- Experience working with hazardous materials.
- Experience writing standard operating procedures and safety work practices documents.
- Experience setting up AM equipment and training others on equipment.
Benefits
Pay Range $87,100.00 - $157,450.00
Pay & Benefits
Pay and benefits are fundamental to any career decision. That's why we craft compensation packages that reflect the importance of the work we do for our customers. Employment benefits include competitive compensation, Health and Wellness programs, Income Protection, Paid Leave and Retirement. More details are available at www.leidos.com/careers/pay-benefits.
About Leidos
All qualified applicants will receive consideration for employment without regard to sex, race, ethnicity, age, national origin, citizenship, religion, physical or mental disability, medical condition, genetic information, pregnancy, family structure, marital status, ancestry, domestic partner status, sexual orientation, gender identity or expression, veteran or military status, or any other basis prohibited by law. Leidos will also consider for employment qualified applicants with criminal histories consistent with relevant laws. Commitment to Non-Discrimination