Additive Manufacturing Engineer, Directed Energy Deposition (DED)

Job Summary

General Atomics Aeronautical Systems, Inc. (GA-ASI) is a leading provider of proven, reliable unmanned aerial systems (UAS) and tactical reconnaissance radars, as well as advanced high-resolution surveillance systems. We are seeking a dynamic and proactive Directed Energy Deposition (DED) Metal Additive Manufacturing Engineer in our Additive Manufacturing (AM) department located in Poway, CA.

Responsibilities

• Subject Matter Expert (SME) on DED metal technologies, with a near-term emphasis on wire-based DED technologies and associated materials.
• Responsible for AM application rapid development and rate production manufacturing workflow, qualification, implementation, and continuous improvement to enhance Quality / Yield, reduce Cost, and improve Productivity / Schedule.
• Initiate and lead lean manufacturing process improvement projects.
• Support manufacturing production planning and coordination, execution and operations process development.
• Support and lead the planning and implementation of AM (incl. post-processing) supply chain, equipment and associated processes and safety.
• Strategize, lead and execute development plans for novel DED convergent manufacturing systems applied to UAS structures.
• Provide production support to internal stakeholders involved in the manufacturing processes associated with DED AM part production and post processing, including interfacing with external strategic suppliers.
• Document manufacturing processes and assembly work instructions in conjunction with T&O Planning.
• Develop, review and/or modifications of AM DED specification documentation with key Materials & Process stakeholders.
• Review engineering drawings, and provide expertise on metal DED during engineering review processes and support new DED application development and risk reduction activities.
• Key interface with engineering stakeholders such as design, materials, process and quality.
• Support and lead technology exploration, assessment and incubation.
• Work closely with DfAM engineering on manufacturing/production operations, and assist with design engineering’s knowledge transfer and teaching efforts.
• Disposition non-conforming parts, identify root cause analysis, and implement corrective and/or preventive action to reduce scrap and rework.
• Collaboratively lead projects for new application development related to DED AM technologies.
• Participation in internal and external AM group representation (e.g. conferences, collaboration groups, executive management reviews, etc.).
• Support with metal DED AM supplier qualification, relationships and visits.
• Support in growth strategy of metal DED AM within AM department and across GA divisions.

Qualifications

• Typically requires a bachelors degree, masters degree or PhD in engineering or a related technical discipline from an accredited institution and progressive engineering experience as follows; four or more years of experience with a bachelors degree or two or more years of experience with a masters degree.
• May substitute equivalent engineering experience in lieu of education.
• Extensive experience with Directed Energy Deposition (DED) technologies metal AM as a designer, and/or as a user of DED to manufacture industrial parts.
• Experience with the entire metal DED AM production workflow from business benefits considerations, design, pre-print considerations and planning, printing, post-processing and qualification process. Specific interest in DED-wire based processes using Titanium and Aluminum materials.
• Experience with metal DED AM printers and associated post-processing equipment and safety procedure.
• Adjacent working knowledge of some other key metal AM technologies, and their associated characteristics and applicability/use cases (e.g. metal LPBF, polymer powder SLS, polymer filament FDM/FFF, etc.).
• Working knowledge of most of AM-relevant metrology and heat treatment technologies applied to metal-DED parts.
• Experience with Design for Additive Manufacturing (DfAM), specifically related to metal DED AM. Ability to demonstrate/provide examples of designs achieved or involved with.
• This assumes some level of proficiency with a major CAD platform (e.g. Siemens Nx, CREO, CATIA, ProE, etc.).
• Experience with metal DED AM suppliers (materials and hardware providers, software providers, contract manufacturers, etc.).
• Background knowledge of conventional manufacturing processes (complementary to metal DED AM, such as CNC machining, casting, forging, welding, etc.).
• Clearly and effectively communicate both verbally and in written form to both technical and non-technical audiences, especially regarding manufacturing processes, engineering issues and proposed changes, and quality issues and dispositions.
• Ability to form and foster rich AM networking and keep engaged.
• Experience with Microsoft Office PowerPoint, Project, Excel and Visio.
• Experience with MRP systems is an advantage, (e.g. SAP).
• Must be able to work both independently and in a team environment.
• Must be self-driven, like to innovate, and with desire to increase his/her knowledge.
• Able to work extended hours occasionally, and travel occasionally as required.
• Able to obtain and maintain DoD Secret Clearance is required.