Additive Manufacturing Engineer

About the role

The Advanced Materials Department is a multi-disciplinary team providing materials engineering expertise for every phase of a program. This position offers a unique opportunity to work on cutting-edge additive manufacturing projects, leveraging a variety of metal additive technologies.

Responsibilities

• Design for additive manufacturing (DfAM)
• Develop plans and layouts for additive manufacturing equipment and capabilities
• Contribute to multiple program teams as the resident additive manufacturing expert across various metal additive technologies
• Perform 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.)

Qualifications

• 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 additional years of experience required in lieu of bachelors degree.
• 4+ years experience in metal additive manufacturing, or MS with 2+ years experience, or PhD with 1+ years experience (8 total minimum years of experience without a college degree).

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 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