Materials Process Engineer - Metals

Responsibilities

• Model thermal conditions during manufacturing processes such as sintering, heat treatment, and casting.
• Create representative models for various manufacturing processes including fluid dynamics, mechanical behavior, heat transfer, and electromagnetic phenomena.
• Use models combined with process data to support process improvement and optimization.
• Build and refine simulations using ANSYS (Mechanical, Maxwell, ROCKY, Fluent), COMSOL Multiphysics, or equivalent commercial simulation platforms.
• Collaborate with process, materials, and data engineers to integrate simulation outputs into process development and optimization workflows.
• Design simulation studies to evaluate process sensitivities, identify failure modes, and guide experimental campaigns.
• Document modeling assumptions, boundary conditions, validation results, and recommendations in a structured manner consistent with quality system requirements.
• Support development of custom scripts and automation tools (Python, MATLAB, or similar) for pre/post-processing of simulation data.

Qualifications

• B.S. or higher in Mechanical Engineering, Aerospace Engineering, Materials Science and Engineering, or a closely related field.
• Demonstrated experience building and validating process models using ANSYS (e.g., Mechanical, Maxwell, ROCKY, Fluent), COMSOL Multiphysics, or equivalent commercial simulation software.
• Strong working knowledge of computational fluid dynamics (CFD), heat transfer modeling, and mechanical stress/strain analysis.
• Proficiency with scripting languages (Python, MATLAB, or similar) for simulation setup, data extraction, and post-processing.
• Ability to work independently, manage multiple concurrent modeling efforts, and communicate results clearly to cross-functional teams.
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.