Metal AM Researcher

About the Role

Shape the future of aerospace defense by leading cutting-edge metal additive manufacturing research at the University of Dayton Research Institute (UDRI). Work includes development, documentation, and validation of a standardized, performance-based qualification framework for AM components, reverse engineering, structural analysis, part prototyping, testing, and qualification of components produced using metal additive manufacturing. This position will lead and collaborate with engineers and scientists at AFRL, requiring strong technical data management and technical writing skills.

Responsibilities

• Develop, document, and validate a standardized, performance-based qualification framework for AM components.
• Perform reverse engineering and structural analysis of metal AM parts.
• Prototype, test, and qualify components produced using metal additive manufacturing.
• Manage technical data and produce technical reports and documentation.
• Lead and collaborate with engineers and scientists at AFRL.

Requirements

Minimum Qualifications (R2)

• Bachelor's degree in engineering or materials science from an accredited university.
• 3 years of experience in metal additive manufacturing or a closely related field.
• Experience operating or designing laser-based manufacturing equipment.
• Firsthand experience with mechanical testing and materials characterization.
• Strong written and verbal communication proficiency.
• Ability to work well with others, think critically, and drive projects to completion with little supervision.
• U.S. citizenship (required due to federal government research contracts).

Preferred Qualifications (R3)

• Meets all R2 minimum qualifications.
• Bachelor’s degree and 8 years of directly related experience, or master’s degree and 7 years of directly related experience, or PhD and 6 years of directly related experience.
• Leadership or technical mentoring experience.
• Ability to work in a team environment and provide technical leadership for supporting personnel and collaborators.

Preferred Qualifications

• Graduate degree in mechanical engineering or materials science from an accredited university.
• Thorough understanding of the metal AM industrial landscape, capabilities, and limitations.
• Familiarity with Airworthiness standards and related qualification requirements.
• Demonstrated experience specifying mechanical testing and material characterization methods and interpreting results.
• Experience with metallurgical characterization for AM materials.
• Experience correlating the effects of LPBF processing parameters to resulting metallurgy.
• Understanding of data acquisition and analysis concepts.
• Ability to perform structural analysis using CAD tools.
• Understanding of metal heat treatment processes and practices.
• Experience performing design of experiments (DOE's) and statistical analysis.
• Understanding of laser/material interaction.
• Demonstrated technical writing ability.