Additive Manufacturing Engineer – R&D

A leading advanced materials manufacturer is seeking an Additive Manufacturing Engineer – R&D to support the development of next-generation metal additive manufacturing processes for high-performance applications across aerospace, defense, semiconductor, medical, energy, and other highly regulated industries.

This is a hands-on R&D role focused on advancing additive manufacturing processes for refractory metal alloys. The successful candidate will be responsible for developing, validating, and documenting scientifically robust material processes that support future commercial applications.

The role will involve process development, material qualification, experimental build activity, powder evaluation, post-processing trials, technical documentation, and close collaboration with engineering, production, and R&D teams.

Key Responsibilities

• Act as the innovation owner for additive manufacturing within the R&D team
• Design and execute Design of Experiments on R&D additive manufacturing equipment
• Evaluate and qualify new refractory metal alloys for future production applications
• Use Statistical Process Control to define material allowables and process capability
• Develop and finalize Qualified Material Process packages where applicable
• Work closely with internal powder production teams to define powder specifications, evaluate new powder batches, and optimize feedstock recycling strategies
• Design and monitor heat treatment and Hot Isostatic Pressing trials to achieve required material properties and reduce internal stresses
• Own process parameters, build strategies, and experimental testing activity on R&D additive manufacturing equipment
• Prepare technical data for internal release, external publications, papers, patents, and industry presentations
• Present technical findings to internal stakeholders and external technical audiences
• Ensure build files, test data, and documentation are stored in line with secure data and compliance requirements
• Collaborate with AM technicians to run experimental builds and testing campaigns
• Transfer validated process packages to production engineering teams for industrialization
• Support verification runs on production printers ahead of new product release

Requirements

• Bachelor’s degree in Materials Science, Metallurgy, Aerospace Engineering, or a related technical field
• Master’s degree or PhD preferred
• 3 years’ experience in metal additive manufacturing process development
• Experience with high-temperature or refractory alloys preferred
• Proven experience with high-temperature post-processing, including HIP and vacuum heat treatment
• 2 years’ experience managing Laser Powder Bed Fusion production builds
• Experience conducting Design of Experiments
• Strong mechanical aptitude and troubleshooting ability
• Proficiency with laboratory and inspection equipment such as microscopes, calipers, and basic measurement tools
• Strong documentation, organization, and attention to detail
• Ability to produce technical research documentation, reports, and publications
• Strong verbal and written communication skills

Preferred Experience

• Powder metallurgy
• General metrology
• Material characterization
• Controlled digital technical data
• Aerospace, defense, semiconductor, medical, or other regulated manufacturing environments
• NASA-STD-6030 or similar material/process qualification standards
• CMMC, CUI, or secure technical data handling environments

Why Apply?

• Opportunity to work at the front end of advanced metal additive manufacturing development
• Exposure to high-performance materials used across aerospace, defense, semiconductor, medical, and energy applications
• Hands-on R&D role focused on material integrity, process qualification, and future commercial applications
• Strong collaboration with technical, production, and materials teams
• Culture focused on technical excellence, operational discipline, and continuous improvement
• Comprehensive benefits package including health, dental, vision, 401(k), and paid time off