Applications Engineer / Production Lead (Additive Manufacturing)

About The Role

We are a production-focused polymer Additive Manufacturing (AM) microfactory built around predictable outcomes: committed Delivery Windows, Evidence Packs with every shipment, and single-custody finishing. Our platform centers on the HP Jet Fusion 5600, supported by AM Solutions S1 depowdering, AMT PostPro SF2X vapor smoothing, and Formlabs Form 4 / 4L SLA. We are not a prototype shop - we are building a repeatable, audit-ready microfactory that customers can plan their production around.

The AE/TL is the founding production engineer and technical backbone of the operation. You own the complete technical lifecycle of every part - from DFAM and file qualification through build preparation, finishing oversight, and Evidence Pack execution - and you keep the HP MJF platform running at its full capability. As our company grows, this role becomes the technical authority for build strategy, process control, and production documentation.

What You'll Own

• Technical Intake & DFAM: Review incoming files for printability and geometry risk; define CTQs (min. 2-3 per order) including measurement methods and acceptance criteria; determine Evidence Pack tier; maintain full traceability of file revisions and design decisions tied to the Job ID.
• Build Preparation & Print Execution: Own all build preparation in Materialise Magics - orientation strategy, packing optimization, mesh repair, and build package documentation for reproducible reorders. Release build travelers with revision locks, finish class, CTQs, and special handling instructions before any job moves to print.
• Post-Processing & Finishing Control: Support S1 depowdering/blasting and finishing cell operations alongside the COO during launch. Apply and log defined finish classes, process recipes, and SF2X vapor smoothing cycle parameters per job. Enforce dirty/clean zone separation to prevent contamination and cosmetic drift.
• Evidence Packs & Traceability: Execute CTQ measurements, standardized photo documentation, and CoC assembly for every shipment. Gate all releases: no job ships without a complete Evidence Pack. Transition evidence ownership to the QA Lead at Month 3; retain CTQ method ownership permanently.
• Formlabs SLA: Own all Form 4 / 4L operations - prototypes, check-fit iterations, fixtures, jigs, inspection aids, and engineering validation parts - with the same job tracking, revision control, and evidence standards applied to HP work.
• Engineering Services: Deliver paid DFAM consulting, tolerance and fit strategy, pilot program planning, fixture design, and additive conversion guidance. These engagements often become long-term production programs.
• Process Development & SOPs: Author SOPs for build prep, finishing, and SLA operations. Participate in weekly defect reviews and root-cause analysis. Contribute real production data to pricing and scheduling models.
  
  

Requried Qualifications

• HP Multi Jet Fusion experience is a firm requirement - no exceptions.
• 2 years of hands-on HP MJF production experience (5200, 5210, 5600, or equivalent) in a production or service bureau environment.
• Working knowledge of MJF process fundamentals: powder refresh/reuse, packing efficiency, cooling cycle management, and common build failure modes.
• Proven ability to troubleshoot dimensional drift, cosmetic surface variation, packing-related defects, and layer or thermal issues.
• Practical DFAM competence for powder-bed polymer AM: wall thickness, feature resolution, mating geometries, and cosmetic A-surfaces.
• Experience defining and measuring CTQs; clear and structured technical documentation skills.
• Materialise Magics build preparation; HP PrintOS platforms.
• Occasional lifting of materials, tools, and/or equipment weighing up to 40 lbs.
  
  

Preferred Qualifications

• Experience printing parts for the Orthotics and Prosthetics Industry is a big plus
• Formlabs SLA systems (Form 3 / 4 / 4L): resin handling, wash/cure protocols, post-cure verification.
• AMT PostPro SF2X vapor smoothing; AM Solutions depowdering/blasting equipment.
• Experience designing fixtures, jigs, or inspection aids for additive manufacturing.
• Background serving O&P, robotics, semiconductor equipment, or medical device customers where traceability and cosmetic consistency are buying criteria.
  
  

What Success Looks Like

• 30 days: Qualification builds complete with documented baseline parameters; first complete Evidence Pack produced; working proficiency in Materialise Magics achieved.
• 90 days: Intake, build prep, and documentation running consistently; Evidence Packs complete for every shipment; SLA workflow operational; key production SOPs drafted.
• 6 months: Repeatable build packages and finishing recipes in place for production programs; rework root causes tracked and declining.
  
  

Why This Role Matters

Additive manufacturing often fails customers because production discipline is missing. The AE/TL exists to solve that problem - ensuring every printed part can be reproduced reliably, documented properly, and delivered on schedule. If you enjoy building production systems, defining technical processes, and owning outcomes from file to shipment, this role offers the opportunity to help build a modern AM microfactory from the ground up.