What are the responsibilities and job description for the Process Engineer position at Fabri?
Application Engineer
Fabri is seeking a highly skilled Process Engineer to join our team and help build the process foundation of a modern digital foundry. In this role, you will lead process development and continuous improvement across ceramic shelling, drying, and thermal processing steps, and upstream photopolymer additive pattern production, driving higher yield, repeatability, and part quality through disciplined experimentation and strong process control.
The Company
We are an early-stage investment casting startup building a fully integrated digital foundry. Our mission is to deliver precision metal castings with unparalleled speed and cost-effectiveness. By leveraging our exclusive high-throughput additive manufacturing process and AI-driven design software, we can deliver castings in days, saving our customers critical time and money. We are well capitalized and backed by top-tier investors and major customers, with significant funding raised in the past year. We’ve shipped our first customer parts and have generated significant commercial excitement in both the aerospace and industrial sectors.
Fabri is located in Boston Metrowest. During this startup phase and for the foreseeable future, all employees will be on-site and closely involved with building and operating the end-to-end process.
Fabri is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. We foster an environment where safety and commitment to quality are central in everything we do.
The Role
Fabri produces low-volume, high-mix investment castings using advanced additive manufacturing and a tightly integrated process workflow. As a Process Engineer, you will own the development and stabilization of the manufacturing steps that most strongly determine final casting quality: (1) ceramic building processes, and (2) additive pattern production (DLP/SLA photopolymers).
You will investigate and reduce defects by understanding underlying mechanisms (wetting dynamics, rheology, optical aberrations, surface bonding mechanisms, materials behavior, stress state, thermal gradients, drying dynamics, gas evolution, handling/fixturing), then translate those learnings into robust process windows, standard work, and scalable production practices.
A key part of this role is partnering closely with Fabri’s software and automation teams to embed manufacturing knowledge into software - turning process rules, constraints, and measurement data into tools that automate decisions, improve traceability, and continuously improve yield.
Responsibilities
Even if you don’t meet every qualification, we encourage you to apply for this role. We value curiosity, problem-solving skills, and strong fundamentals.
Preferred Skills
Apply through our online portal at:
https://app.dover.com/jobs/fabri-usa
Fabri is seeking a highly skilled Process Engineer to join our team and help build the process foundation of a modern digital foundry. In this role, you will lead process development and continuous improvement across ceramic shelling, drying, and thermal processing steps, and upstream photopolymer additive pattern production, driving higher yield, repeatability, and part quality through disciplined experimentation and strong process control.
The Company
We are an early-stage investment casting startup building a fully integrated digital foundry. Our mission is to deliver precision metal castings with unparalleled speed and cost-effectiveness. By leveraging our exclusive high-throughput additive manufacturing process and AI-driven design software, we can deliver castings in days, saving our customers critical time and money. We are well capitalized and backed by top-tier investors and major customers, with significant funding raised in the past year. We’ve shipped our first customer parts and have generated significant commercial excitement in both the aerospace and industrial sectors.
Fabri is located in Boston Metrowest. During this startup phase and for the foreseeable future, all employees will be on-site and closely involved with building and operating the end-to-end process.
Fabri is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. We foster an environment where safety and commitment to quality are central in everything we do.
The Role
Fabri produces low-volume, high-mix investment castings using advanced additive manufacturing and a tightly integrated process workflow. As a Process Engineer, you will own the development and stabilization of the manufacturing steps that most strongly determine final casting quality: (1) ceramic building processes, and (2) additive pattern production (DLP/SLA photopolymers).
You will investigate and reduce defects by understanding underlying mechanisms (wetting dynamics, rheology, optical aberrations, surface bonding mechanisms, materials behavior, stress state, thermal gradients, drying dynamics, gas evolution, handling/fixturing), then translate those learnings into robust process windows, standard work, and scalable production practices.
A key part of this role is partnering closely with Fabri’s software and automation teams to embed manufacturing knowledge into software - turning process rules, constraints, and measurement data into tools that automate decisions, improve traceability, and continuously improve yield.
Responsibilities
- Lead root-cause analysis and corrective actions for defects across printing, shelling/drying, thermal processing, and downstream casting outcomes, with a focus on how the introduction of additively manufactured patterns influence the traditional casting process.
- Design and execute rigorous experimentation programs (DOE), including statistical analysis, measurement system validation, and clear decision criteria.
- Develop and optimize coating process parameters, slurry chemistry (polymer systems, binder systems, solids loading, rheology), stucco strategy, drying conditions, layer schedules, handling/fixturing.
- Develop and optimize burnout and thermal processing of printed patterns to improve shell integrity and dimensional stability, including printed infill geometries, polymer chemistry, furnace profiles, ramp/soak schedules, venting strategies, orientation, and fixture design.
- Own and improve the photopolymer pattern process: printer parameter development, resin handling, resin chemistry, pattern post-processing, print reliability, dimensional stability, throughput, and influence on subsequent process steps.
- Define key process metrics and implement process controls (SPC where appropriate), including monitoring plans and alarm thresholds.
- Build characterization and metrology workflows with quality teams to quantify defects and validate improvements (e.g., sectioning, microscopy, dimensional/scan-based methods), and ensure the right data is collected for feedback and reporting.
- Collaborate with software/automation teams to encode process rules and constraints into production software (e.g., parameter capture, recipe management, traceability, defect tagging, data collection) and to close the loop between process outcomes and automated decision-making.
Even if you don’t meet every qualification, we encourage you to apply for this role. We value curiosity, problem-solving skills, and strong fundamentals.
- Bachelor’s degree in Materials Science/Engineering, Ceramic Engineering, Chemical Engineering, Mechanical Engineering, or a related field.
- 3 years of experience in hands-on process engineering, process development, or manufacturing engineering (investment casting, additive manufacturing, surface engineering, polymer science, ceramics, thermal processing, or related).
- Demonstrated ability to run disciplined DOE programs and apply statistical methods to manufacturing processes.
- Comfort working on the factory floor and owning outcomes in a fast-paced, multidisciplinary environment.
- Strong attention to detail and disciplined documentation habits.
- Strong communication skills and ability to collaborate closely with operations, quality, and software teams.
Preferred Skills
- Familiarity with surface engineering, optics, thermo and fluid dynamics, rheology, colloids/suspensions, binders, surfactants, and drying/curing kinetics.
- Experience with thermal decomposition and processing of polymers and ceramics, and furnace operation, including fixture design and thermal stress mitigation.
- Experience with optical additive manufacturing processes and post-processing (DLP/SLA or related), especially where thermal processing compatibility matters.
- Experience with SPC, capability analysis, yield tracking, and structured quality systems.
- Experience collaborating with software teams to instrument processes and build data-driven feedback loops.
- Ability to rapidly identify, learn, and reason across diverse, multi-disciplinary physics domains and process steps using a systems-engineering mindset, applying first-principles and strong theoretical fundamentals to solve complex problems efficiently.
- Experience in a startup with high ownership and ambiguity.
- Opportunity to play a central role in delivering parts to customers at a cutting-edge digital foundry, and Fabri’s mission to rebuild the US foundry industry.
- Opportunity to take significant ownership of some of the most complex challenges in advanced manufacturing, while developing and applying a highly multidisciplinary skill set spanning nearly all domains of physics.
- Direct impact on customer satisfaction, product quality, and internal process improvement.
- Collaborative, hands-on work environment with close interaction across engineering and manufacturing.
- Competitive salary, meaningful equity, and strong growth opportunities.
Apply through our online portal at:
https://app.dover.com/jobs/fabri-usa
Salary : $125,000 - $150,000