Process Engineer

Process Engineer – Additive Manufacturing

Azul 3D is looking for a Senior Process Engineer to own and advance the printing process that enables production-quality parts.

This role sits at the intersection of hardware, software, optics, and materials. Your responsibility will be to understand how every aspect of the printing system—from optical exposure and process parameters to hardware architecture and resin formulation—affects final part performance.

You will design experiments, build process models, and develop robust manufacturing processes that deliver improvements in dimensional accuracy, material properties, surface finish, throughput, and repeatability. You'll work closely with hardware, software, and materials teams to influence the evolution of the entire printing platform.

This is an ideal role for someone who has previously developed or optimized additive manufacturing processes for a commercial 3D printing platform.

What You'll Do

• Own process development objectives for Azul's HARP(tm) manufacturing platform.
• Develop and optimize print recipes that maximize dimensional accuracy, material properties, repeatability, and production throughput.
• Design and execute rigorous DOE studies to understand process interactions and define robust operating windows.
• Characterize relationships between exposure strategy, hardware configuration, resin chemistry, thermal management, and final part performance.
• Partner with hardware, software, and materials teams to improve printer architecture and manufacturing capability.
• Develop metrology methods and statistical analyses to quantify process capability.
• Transition optimized processes from R&D into scalable manufacturing.
• Solve complex interdisciplinary problems using experimental data and first-principles engineering.

We're Looking For

• BS, MS, or PhD in Chemical Engineering, Materials Science, Mechanical Engineering, Manufacturing Engineering, or related field.
• 5 years developing manufacturing or additive manufacturing processes.
• Experience optimizing production 3D printing systems at the platform level.
• Strong background in Design of Experiments (DOE), statistical analysis, and process optimization.
• Experience relating process parameters to mechanical properties, dimensional accuracy, and manufacturing consistency.
• Understanding of photopolymerization, reaction kinetics, heat transfer, fluid mechanics, or optical systems.
• Excellent experimental design and data analysis skills.
• Ability to work across hardware, software, materials, and manufacturing teams.

Bonus Points

• Experience at a commercial additive manufacturing hardware OEM or materials supplier
• Experience in vat photopolymerization or UV ink-jetting
• Experience developing print strategies or exposure algorithms.
• Experience in optical physics
• Experience in full cycle R&D, from early research to commercial launch
• Knowledge of photopolymer chemistry or resin formulation.
• Programming experience (Python, MATLAB, JMP, or similar).
• Experience with statistical process control and manufacturing scale-up.

• Salary: $80,000–$140,000, based on experience
• Equity

• Medical, dental, and vision insurance
• 401(k) with matching
• Generous PTO and paid holidays
• Parental Leave