Senior Applications Development Engineer

About Us

Founded in 2015 to develop the world’s first industrially scalable laser metal additive manufacturing solution, VulcanForms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting-edge technology with a foundation of proven industrial craftsmanship. Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.

Job Purpose

As a Senior Applications Development Engineer at VulcanForms, your mission is to design and optimize our high-speed laser-powder-bed-fusion process and its digital workflow to deliver production-ready parts at scale. You’ll collaborate across hardware, software, and operations teams to continuously improve print quality, system reliability, and workflow efficiency – enabling transformative outcomes for our customers and the future of advanced manufacturing.

Key Responsibilities

• Partner with hardware, software and operations teams to develop and implement integrated process – from R&D through pilot runs to full serial production – achieving high manufacturing readiness levels.
• Create and iterate LPBF process recipes and build configurations, including build files, post-process sequences, and machine integration to ensure consistent production of parts within the VulcanForms platform.
• Translate user requirements into engineering specifications that guide end-to-end product and process development; collaborate with internal teams to optimize part designs for LPBF, balancing geometry, supports, tolerances and material performance.
• Build and iterate parts, hardware, and tools to support First Article Inspection and production launches of products in medical, aerospace, consumer, defense, and other industries.
• Serve as the technical interface with customers, program managers, and operations leaders – communicating development status, sharing findings, troubleshooting issues, and aligning on production plans.
• Own root cause analysis of print defects and drive corrective actions through rapid iteration and testing.
• Develop application-specific process workflows that meet customer requirements for dimensional accuracy, mechanical performance and surface finish.
• Collaborate with downstream process owners in machining, finishing, and other areas to implement DFM principles with a top-down approach.
• Collaborate with operations and quality teams to establish standard operating procedures and quality control methods.
• Create and maintain detailed documentation: build recipes, work instructions, inspection protocols, change logs and training materials – ensuring repeatability, traceability and production compliance.
  
  

Qualifications

• Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a related field; Master’s or Ph.D. preferred.
• Minimum of 2 years hands-on experience in product or applications development, preferably with a focus on LPBF or directed energy deposition (DED) processes.
• Proficiency in 3D CAD software such as Siemens NX, Creo, or SolidWorks.
• Solid understanding of GD&T, tolerance analysis, and design for manufacturability (DFM) principles.
• Familiarity with quality management systems and associated standards.
• Strong interpersonal and communication skills with the ability to collaborate effectively across multidisciplinary teams.
• Knowledge of subtractive manufacturing operations (e.g. milling, turning) and their design constraints is a plus.
  
  

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match.

The annual base salary range for this position is $97,600-$134,200.