Director of Quality, Additive Manufacturing

Hadrian - Manufacturing the Future Hadrian is building autonomous factories that help aerospace and defense companies manufacture rockets, satellites, jets, and ships up to 10x faster and up to 2x cheaper. By combining advanced software, robotics, and full-stack manufacturing, we are reinventing how America produces its most critical parts. We’re accelerating our mission with the launch of Factory 3 in Mesa, Arizona, a 290,000-square-foot facility creating 350 new jobs. We are expanding rapidly to support thousands of future hires, launching Hadrian Maritime to expand into naval production, and introducing a Factory-as-a-Service model that delivers complete systems instead of individual parts. Hadrian is backed by leading investors including T. Rowe Price, Lux Capital, Founders Fund, and Andreessen Horowitz, our fast-growing team is united around reindustrializing American manufacturing for the 21st century and beyond. The Role: This is a hands‑on leadership role for a true AM quality expert. You will own the full qualification lifecycle, from Installation Qualification (IQ) through Operational Qualification (OQ) and Material Qualification (MQ), ensuring Hadrian's processes meet or exceed the requirements of AMS 7003, AMS 7032, NASA-STD-6030/6033, NAVSEA Technical Publications, and prime customer specifications. This role spans multiple AM modalities, including Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED) processes, with specific emphasis on Wire Arc Additive Manufacturing (WAAM) qualification for U.S. Navy and submarine industrial base applications. You will be responsible for qualification across both PBF-LB and DED; however, deep hands‑on expertise in one of these modalities is required, with working knowledge of the other sufficient to provide technical direction and grow into full ownership. You will work cross‑functionally with Hadrian's Materials and Process (M&P) team, Applications team, and Systems team to achieve results. In this model, you own the requirement set, including qualification criteria, process control standards, KPV limits, and acceptance specifications, while the M&P, Applications, and Systems teams conduct the implementation. Your deep knowledge of AM process physics, laser and/or arc‑based energy sources, feedstock metallurgy, and qualification methodology will be the foundation on which Hadrian builds a scalable, auditable, and production‑ready AM operation. What You’ll Do: Cross‑Functional Requirements Ownership: Own the AM quality requirement set across Hadrian's operations. Collaborate with the Materials and Process (M&P) team, Applications team, and Systems team to define qualification criteria, process control standards, KPV limits, material acceptance specifications, and documentation requirements. Ensure requirements are clearly communicated and properly implemented through ongoing oversight and compliance verification. Serve as the quality authority during cross‑functional reviews, providing technical direction while partner teams execute implementation activities. Machine Qualification and Process Validation: Own the end‑to‑end qualification framework for AM equipment, including IQ, OQ, and MQ. Define qualification requirements, acceptance criteria, and test matrices. Collaborate with the Materials and Process (M&P) team to develop build layouts and qualification plans; M&P executes those plans while this role provides oversight and ensures compliance. Ensure all machines are maintained in a known, calibrated state with active qualification status. KPV Management and Process Control: Define and own the requirements for Key Process Variables including laser power, beam caustics (spot size, shape, M2, thermal shift, location of focus), scan field calibration, shielding gas flow, and oxygen content. Collaborate with M&P and Systems teams to establish tolerance bands, measurement frequencies, SPC programs, and process window studies per AMS 7003 and AMS 7032 guidance. Ensure ongoing compliance through oversight and review of KPV data. Laser Diagnostics and Beam Characterization: Define requirements and acceptance criteria for all laser power measurement, beam profiling, and caustic measurement activities. Collaborate with M&P to specify beam profiling equipment and define measurement protocols. Provide oversight of measurement execution and interpret results to ensure laser systems are performing within qualified parameters. Gas Flow Measurement and Control: Define requirements for gas flow characterization across build platforms, including measurement methods, acceptance criteria, and correlation to part quality. Collaborate with M&P on execution of anemometer‑based measurements and flow mapping. Ensure airflow consistency is validated during IQ and monitored through PM. DED and WAAM Qualification: Own the qualification framework for Directed Energy Deposition processes, with specific focus on Wire Arc Additive Manufacturing (WAAM) for U.S. Navy and submarine industrial base applications. Collaborate with M&P to define process control requirements, qualification test plans, and acceptance criteria for DED/WAAM in accordance with NAVSEA Technical Publications, AWS D20.1, and applicable defense standards. Provide oversight of qualification execution and ensure methodology supports NAVSEA technical warrant holder approval for AM production. Standards Compliance and Regulatory Readiness: Serve as the subject matter expert on AMS 7003, AMS 7032, NASA-STD‑6030, NASA-STD‑6033, NAVSEA Technical Publications for PBF and DED, AWS D20.1, and applicable prime customer specifications. Maintain awareness of evolving AM standards from SAE, ASTM, ISO, AWS, and Nadcap. Ensure Hadrian's quality systems and process control documents align with current and anticipated requirements. NIAR Qualification Framework, JAQS‑SQ, and Navy AM COE Alignment: Stay current with NIAR's work on AM machine qualification, OQ guidance, the Joint Additive Qualification for Sustainment, Supplier Qualification (JAQS‑SQ) program, and the U.S. Navy's Additive Manufacturing Center of Excellence (AM COE) activities. Leverage these frameworks to inform Hadrian's internal qualification strategy and ensure alignment with DoD and Navy supplier readiness expectations. Powder Quality and Material Control: Own the requirements for feedstock quality across both powder and wire processes, including incoming inspection criteria, lot control standards, storage and handling requirements, reuse methodology, and contamination prevention. Collaborate with M&P to develop and implement procedures aligned with AMS 7002 and alloy‑specific powder specifications. For wire feedstock, collaborate with M&P to ensure chemistry, surface condition, size tolerance, and traceability requirements are met. Provide oversight of powder reuse procedures, sampling plans, and sieve management protocols to ensure ongoing compliance. Material Qualification and Testing: Define target material properties, acceptance criteria, and testing requirements. Collaborate with M&P to develop test plans and manage mechanical testing campaigns (tensile, fatigue, compression, metallography, chemistry). Provide oversight to ensure OQ builds meet material specification requirements across all qualified orientations and build areas. Quality Systems and Documentation: Own the requirements for AM‑specific process control documents (PCDs) including facility control plans, operator training programs, work instructions, digital file configuration control, PM plans, calibration verification plans, machine requalification plans, and KPV plans. Collaborate with M&P, Applications, and Systems teams on document development. Ensure all documentation is compliant and integrated into Hadrian's Quality Management System. Supplier Quality Oversight: Collaborate with Supply Chain and M&P to define technical quality requirements for AM suppliers. Provide oversight of qualification audits, process reviews, nonconformance management, SCAR issuance, and CAPA verification. Ensure suppliers maintain compliant quality systems and produce material that meets Hadrian's requirements. Requalification and Verification Management: Own the requalification framework, including triggers and verification event criteria. Collaborate with M&P and Systems teams to assess the impact of machine changes, maintenance activities, software updates, component replacements, and environmental changes on qualification status. Determine appropriate response levels (full OQ, partial OQ, or verification) and ensure compliance through oversight of remediation activities. Preventative Maintenance Program: Define PM requirements for all AM equipment, including verification items, intervals, measurement protocols, and documentation requirements. Collaborate with Operations on PM plan development and execution. Ensure PM activities are traceable and that any findings are assessed for impact to qualification status. New Product Introduction (NPI): Collaborate with Applications and M&P teams to support launch of new AM components through APQP, PPAP, and AS9102 First Article Inspection. Define quality requirements and acceptance criteria for NPI. Ensure process readiness, qualification completeness, and compliance prior to production ramp‑up. Design for Additive Manufacturability (DfAM): Collaborate with engineering teams to provide quality and manufacturability input, including build orientation, support strategy, downskin parameter effects, and as‑built surface finish implications. Represent process capability and quality risk during design reviews. Continuous Improvement: Define quality improvement priorities across AM operations. Collaborate with M&P and cross‑functional teams on execution of improvement initiatives using Six Sigma, FMEA, SPC, and Lean methodologies. Ensure gaps in process capability, measurement systems, and documentation are identified and closed. Team Leadership: Build and lead a team of AM quality engineers. Set execution cadence, coach technical development, and ensure fast, rigorous response to quality issues. What We’re Looking For: Bachelor's degree in Engineering (Mechanical, Materials, Industrial, or related); Master's degree is a plus. 8+ years of experience in additive manufacturing quality engineering, with direct, hands‑on experience qualifying equipment and processes for aerospace, defense, or spaceflight applications. Deep expertise in at least one of the following AM modalities, with working knowledge of the other: (a) Laser Powder Bed Fusion (PBF‑LB), including machine qualification, laser diagnostics, and powder management; or (b) Directed Energy Deposition (DED), including WAAM process qualification, arc‑based process controls, and wire feedstock management. This role will be responsible for qualification across both modalities. Demonstrated experience executing IQ, OQ, and MQ on AM machines, including build layout design, test plan development, and material property evaluation. Deep working knowledge of AMS 7003, AMS 7032, and AMS 7002, including process control documents, KPV identification and control, and powder management requirements. Experience qualifying AM equipment to AMS 7032, NASA-STD‑6030, NAVSEA Technical Publications for PBF and/or DED, or to prime customer AM specifications with equivalent rigor. Hands‑on experience with laser power measurement, beam caustic/profiling equipment, and interpretation of beam quality data (spot size, M2, thermal shift, location of focus, astigmatism). Hands‑on experience with gas flow measurement methods and characterization of shielding gas performance across build platforms. Strong understanding of powder metallurgy, including powder quality requirements, particle size distribution, chemistry, morphology, lot control, reuse methodology, and contamination prevention per AMS 7002 and AMS 7001. Familiarity with wire feedstock quality requirements for DED/WAAM processes. Skilled in root cause analysis (8D, 5 Whys, Fishbone), CAPA, and nonconformance management. Deep understanding of AS9100, Nadcap for AM, GD&T, PPAP, APQP, FMEA, and SPC. Excellent communication and cross‑functional leadership abilities. Willing to travel up to 20%, primarily within the U.S., with occasional international travel. U.S. Citizen or Permanent Resident (required for ITAR compliance). What Will Set You Apart: Experience with WAAM qualification for U.S. Navy applications, including familiarity with NAVSEA qualification requirements, technical warrant holder approval processes, and the Navy's Additive Manufacturing Center of Excellence (AM COE) in Danville, VA. Familiarity with DED‑specific standards including AWS D20.1, AMS 7004, AMS 7005, and ASTM F3187. Familiarity with the NIAR Operational Qualification Guidance Document and related NIAR/America Makes work on AM machine qualification methodology. Awareness of the JAQS‑SQ (Joint Additive Qualification for Sustainment, Supplier Qualification) program and its implications for DoD AM supplier readiness. ASQ Certified Quality Engineer (CQE), AS9100 Lead Auditor, or Six Sigma (Green/Black Belt). Familiarity with AM standards such as ASTM F42, ISO 52900, SAE AMS 7XXX Series, and Nadcap requirements for AM. Active involvement in standards committees (e.g., ASTM F42, SAE AMS, ISO TC 261). Experience with AM in‑situ process monitoring (meltpool monitoring, optical tomography, recoat monitoring) and its application to quality assurance. Experience with CT scanning, metallurgical analysis, and advanced NDE methods for AM parts. Understanding of multi‑laser systems, laser zone strategies, stitching qualification, and scan field calibration for multi‑laser LPBF platforms. Proven leadership in team‑building and quality system development in fast‑paced or startup environments. Knowledge of other manufacturing processes (e.g., CNC, casting, welding, composites). Experience transitioning AM products from R&D to full‑scale production. Proficiency with digital QMS, inspection software, and PLM platforms. Compensation: For this role, the target salary range is $220,000 - $250,000 (actual range may vary based on experience). This is the lowest to highest salary we reasonably and in good faith believe we would pay for this role at the time of this posting. We may ultimately pay more or less than the posted range, and the range may be modified in the future. An employee's pay position within the salary range will be based on several factors, including, but not limited to, relevant education, qualifications, certifications, experience, skills, geographic location, performance, and business or organizational needs. Benefits for Full-time Employees Medical, dental, vision, and life insurance plans for employees 401k Relocation support may be provided for certain situations, based on business need. Flexible vacation policy ITAR Requirements To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State. Learn more here. Hadrian Is An Equal Opportunity Employer It is the Company’s policy to provide equal employment opportunity for all applicants and employees. The Company does not unlawfully discriminate on the basis of race inclusive of traits historically associated with race (including, but not limited to, hair texture and protective hairstyles, such braids, locks and twists), color, religion, sex (including pregnancy, childbirth, or related medical conditions), gender identity, gender expression, transgender status, national origin (in California, possession of a driver's license), ancestry, citizenship, age, physical or mental disability, height or weight, medical condition, family care status, military or veteran status, marital status, domestic partner status, sexual orientation, genetic information, exercise of reproductive rights, any other basis protected by local, state, or federal laws, or any combination of the above characteristics. When necessary, the Company also makes reasonable accommodations for disabled candidates and employees and, how is... (the paragraph truncated?) ... #J-18808-Ljbffr