Sr Metal Additive Process Engineer

Position Summary
Lead the development, optimization, and scale-up of metal additive manufacturing (metal 3D printing) processes through hands-on operation of metal printing equipment, experimental design, and data analytics. Drive process understanding, establish robust manufacturing windows, and qualify parts and components.

Key Responsibilities
Operate, maintain, and optimize metal additive manufacturing systems.
Develop and refine print parameters to improve build quality, productivity, and yield.
Design and execute DOE studies to identify and optimize critical process parameters.
Troubleshoot printing, powder handling, and post-processing issues using engineering and statistical methods.
Support equipment and part qualification, process validation, and scale-up into production.

Must-Have Skills
Hands-on experience with metal additive manufacturing technologies.
Strong understanding of metal powder behavior, melt pool dynamics, process parameter development, and defect mechanisms.
Experience designing and executing DOE studies and applying statistical analysis.
Strong troubleshooting and root-cause investigation skills.

Nice-to-Have Skills
Machine learning, AI, or predictive modeling for process optimization.
Design for Additive Manufacturing (DfAM).
Thermal modeling, FEA, or simulation of metal AM processes.

Preferred Qualifications
BS/MS in Mechanical Engineering, Materials Science, Manufacturing Engineering, or related discipline.
5+ years minimum of experience in metal additive manufacturing process development. (7-10 years' experience would be preferred)