Additive Manufacturing & Metallurgical Lead

Would you like to be part of a highly technical, collaborative, and multifaceted team with expertise that spans the disciplines of aerospace, mechanical engineering, and physics?

Do you enjoy solving challenges related to materials science and its applications in missile systems?

Do you have a passion for finding solutions to current and emerging materials challenges for the Department of Defense (DoD)?

If so, then we’re looking for someone like you to join our Materials Engineering section!

As a section our mission focuses on innovation, integration, and characterization of materials for missile defense. We operate at the intersection of material innovation, modeling, damage mitigation, and energetics. Joining this section means working with state-of-the-art facilities, subject matter experts, and a supportive team of materials scientists and engineers.

With a focus on advanced propulsion, next generation interceptors and structural integrity, we are seeking a subject matter expert in Metallurgy and Additive Manufacturing (AM) to revolutionize the production of aerospace propulsion and structural systems. This role is central to the development of future defensive missiles and other high-performance projectiles. By leveraging Directed Energy Deposition (DED) and novel alloy design, you will create components that are lighter, stronger, and more heat-resistant than legacy hardware, directly impacting the kinematic reach and lethality of US defense systems.

As a Additive Manufacturing & Metallurgical Lead you will....

• Alloy Innovation: Design and qualify proprietary alloys for metal 3D printing that provide enhanced structural integrity at temperatures exceeding current industry standards
• Propulsion Enhancement: Apply additive manufacturing to create complex, high-efficiency rocket nozzles and engine components that enable greater interceptor speed and maneuverability
• Multi-Functional Materials: Develop reactive structural materials and metallized fuels that integrate structural support with enhanced energetic performance
• Failure Analysis & Mitigation: Use advanced characterization and techniques to predict damage growth mechanisms from EMP, kinetic impact, and thermal stress in printed components
• Advanced Infrastructure: Oversee the fabrication of resilient defense infrastructure components, utilizing AM to reduce maintenance cycles and improve system-level reliability
• Alloy Engineering: Develop and optimize metal powders and feedstock for AM/DED processes, focusing on improving creep resistance and thermal stability
• Advanced Manufacturing: Lead efforts in Directed Energy Deposition to create complex, multi-functional geometries for aerospace propulsion and structural systems
• Mechanical & Chemical Evaluation: Evaluate material performance under combined loads, including kinetic, thermal, and chemical stressors
• Damage Assessment: Analyze damage growth mechanisms in printed parts, specifically looking at high-velocity impact and environmental degradation (e.g., oxidation)
• Mission Support: Contribute to the development of reactive structural materials to enhance the kinematic capabilities and lethality of missile/projectile systems

You meet our minimum qualifications for the job if you...

• Possess an BS in Metallurgical Engineering, Materials Science and Engineering or Materials Engineering, with a minimum of five years of related experience
• Have demonstrated hands-on expertise with metal additive manufacturing and alloy designs platforms
• Have a strong background in physical metallurgy and hands-on expertise with DED and powder-bed fusion platforms
• Are able to correlate micro-structural evolution during the AM process with macro-scale performance in extreme aerospace environments
• Have excellent communication skills to interface with sponsors, contractors, and Program Managers
• Can obtain an interim Secret-level security clearance by your start date and can ultimately obtain a Secret-level clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship

Why Work at APL?

The Johns Hopkins University Applied Physics Laboratory (APL) brings world-class expertise to our nation’s most critical defense, security, space and science challenges. While we are dedicated to solving complex challenges and pioneering new technologies, what makes us truly outstanding is our culture. We offer a vibrant, welcoming atmosphere where you can bring your authentic self to work, continue to grow, and build strong connections with inspiring teammates.

At APL, we celebrate our differences of perspectives and encourage creativity and bold, new ideas. Our employees enjoy generous benefits, including a robust education assistance program, unparalleled retirement contributions, and a healthy work/life balance. APL’s campus is located in the Baltimore-Washington metro area. Learn more about our career opportunities at  .

All qualified applicants will receive consideration for employment without regard to race, creed, color, religion, sex, gender identity or expression, sexual orientation, national origin, age, physical or mental disability, genetic information, veteran status, occupation, marital or familial status, political opinion, personal appearance, or any other characteristic protected by applicable law. APL is committed to providing reasonable accommodation to individuals of all abilities, including those with disabilities. If you require a reasonable accommodation to participate in any part of the hiring process, please contact  View email address on apply.j-vers.com .

The referenced pay range is based on JHU APL’s good faith belief at the time of posting. Actual compensation may vary based on factors such as geographic location, work experience, market conditions, education/training and skill level with consideration for internal parity. For salaried employees scheduled to work less than 40 hours per week, annual salary will be prorated based on the number of hours worked. APL may offer bonuses or other forms of compensation per internal policy and/or contractual designation. Additional compensation may be provided in the form of a sign-on bonus, relocation benefits, locality allowance or discretionary payments for exceptional performance. APL provides eligible staff with a comprehensive benefits package including retirement plans, paid time off, medical, dental, vision, life insurance, short-term disability, long-term disability, flexible spending accounts, education assistance, and training and development. Applications are accepted on a rolling basis.