Additive Manufacturing Process Engineer (Onsite)

About the role

The Collins Aerospace Additive Design and Manufacturing (ADaM) team is seeking an Additive Manufacturing (AM) Process Engineer for its Monroe, NC Additive Manufacturing facility.

Responsibilities

• Own MES usage architecture for AM processes, including standard operations, workflows, and process plan setup;
• Define and maintain AM process parameters, specifications, and controlled process documentation (WIs, traveler elements, workflow logic).
• Execute and document IQ, OQ, and MQ qualifications for equipment and processes, ensuring validated, compliant, and traceable process baselines.
• Lead SPC tracking, process capability analysis, and performance monitoring to assess process health and drive data-based improvements.
• Support production builds by troubleshooting process issues, validating parameter sets, and providing technical guidance to Operations and Quality.
• Develop build layouts, optimized manufacturing processes, and cell-level process designs to improve efficiency, robustness, and throughput.
• Generate and maintain Golden Files as part of NPI Gate 4 activities to establish frozen, qualified process configurations.
• Lead PPAP-related process inputs including Control Plans, PFMEAs, process flow diagrams, and validation evidence.
• Create standardized, reusable process templates that guide future production execution and enable efficient configuration by the Project Engineer.
• Collaborate with Materials Scientists to ensure process parameters and material behaviors are correctly linked within MES and reflected in process performance.
• Work closely with Quality Engineering on nonconformance investigations, root cause analysis, corrective actions, and integration of quality controls into the QMS/MES.
• Provide technical input to Operations, supporting work instructions, technician readiness, build setups, and troubleshooting of process-related disruptions.
• Align with the Digital Systems & SIOP Lead to integrate process logic, SPC data, and system automation into digital tools and MES workflows.
• Drive continuous improvement projects to enhance process capability, yield, stability, and alignment with SPQDC objectives.
• Travel up to 10%.

Qualifications

• Typically requires a University Degree and minimum 5 years prior relevant experience or an Advanced Degree in a related field and minimum 3 years of experience.
• 3+ years of experience with laser powder bed fusion metal additive manufacturing, including process parameters, process controls, and machine functionality (laser behavior, build environment, powder handling, etc.).
• 3+ years of experience developing, validating, or sustaining manufacturing processes, including process documentation, workflow control, and troubleshooting processes.
• 2+ years of experience with MES, process architecture, or digital manufacturing workflows (e.g., defining steps, routings, or parameter-driven operations).
• Master’s degree in science, engineering, materials science, or other related field.
• Experience with process validation activities (IQ/OQ/MQ), PFMEA, Control Plans, or PPAP-related documentation.
• Familiarity with AM or special process specifications and standards (e.g., AMS, NASA-STD, customer-specific process requirements).
• Hands-on experience with SPC tools, process-health monitoring, or development of controlled parameter sets.
• Experience with traditional manufacturing processes involving metals, including troubleshooting process variability.
• Strong analytical and problem-solving skills, with the ability to interpret data and drive process capability improvements.
• Ability to work effectively in a cross-functional engineering environment and communicate technical information clearly.

Benefits

We offer a comprehensive benefits package including medical, dental, and vision insurance, three weeks of vacation, a generous 401(k) plan with employer matching, tuition reimbursement, and more!