Additive Manufacturing Process Development Engineer

Job Title: Additive Manufacturing Process Development Engineer

Reports To: Process Engineering Manager-Cold Spray

FLSA Status: Exempt

Prepared Date: October 25, 2026

SUMMARY: The AM Process Development Engineer will design, develop, and produce Additive Manufacturing processes and evaluation procedures. In addition, the AM Process Development Engineer will facilitate development and testing of process conditions, motions system control, and all secondary processing required in support of company capabilities development and application development for various processes.

QUALIFICATIONS: To perform this job successfully, the individual must be able to perform each essential duty and responsibility in a safe and satisfactory manner. The requirements listed below are representative of the knowledge, skill, and/or ability required.

ESSENTIAL JOB FUNCTIONS:

· Develop advanced additive manufacturing (AM) processes and procedures for various materials.

· Collaborate with equipment designers and other process development engineers to plan and execute projects focused on material and part quality.

· Operate and maintain equipment like cold spray, friction stir, and wire-DED equipment, robotics, mechanical testing frames, hardness testers, grinding/polishing equipment, light optical microscopes, machine shop tools and machines.

· Adjust variables in AM processes to improve existing build procedures and create new ones.

· Evaluate generated test data and troubleshoot processes and associated equipment.

· Build reports using Microsoft Office (Excel, PowerPoint, and Word) that summarize project efforts for internal and external reporting to customers.

· Develop long-term planning to coordinate multiple complex development activities with other VRC engineering functions.

· Maintain documentation of processes that conform to AS9100D requirements.

Reasonable accommodations may be made to enable individuals with disabilities perform the essential functions. Other duties may be assigned.

WAGES/SALARY:

$100,000 - $130,000 per year

SUPERVISORY RESPONSIBILITIES:

None

EDUCATION and EXPERIENCE:

· Minimum of 5 years of Additive Manufacturing Experience

· Bachelor of Science in Engineering or related professional qualification required

· Solid understanding of engineering systems and function, at individual component and system levels.

· Knowledge of AM processes a must.

· Knowledge of heat transfer, residual stresses, materials behavior, and defects in AM parts.

· Understanding of analytical and numerical methods for modeling and simulations of processes.

· Understanding of robotics systems.

· Interdisciplinary project management experience

· Production AM experience a plus

LANGUAGE SKILLS:

· Read and interpret documents in English such as safety rules, , operating and maintenance instructions, and procedure manuals, newspapers, periodicals, journals, and equipment manuals. 

· Ability to develop, write, format, and communicate policies and procedures

· Write routine business and technical reports, correspondence, business letters, summaries, and reports in English using prescribed format, and conforming to all rules of punctuation, grammar, diction, and style

· Speak effectively in English before groups such as customers or other employees

· Ability to develop and maintain a professional working relationship with all team members.

COMPUTER SKILLS:

· Microsoft Word, Power Point, and Excel at an advanced level and be familiar with the use of Microsoft Teams and OneNote.

· Proficient in CAD/CAM software, and robotics programming software highly desired.

· Proficient in AM path planning tools including writing software and scripts to enable unique AM applications.

· Proficient in electronic forms of communication including email, web searching, and data organization.

REASONING ABILITY:

· Apply common sense understanding to carry out instructions furnished in written, oral, or diagram form.

· Use mathematical skills to interpret mechanical and metallurgical findings, financial information, and prepare budgets.

PHYSICAL DEMANDS:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. While performing the duties of this job, the employee is regularly required to stand; walk; use hands to finger, handle, or feel; reach with hands and arms; stoop, kneel, crouch, or crawl; and talk or hear. The employee must regularly lift and/or move up to 10 pounds and frequently lift and/or move up to 25 pounds. The employee must be able to see differences in widths and lengths of lines such as those on graphs. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

ENVIRONMENTAL CONDITIONS:

Inside: Protection from weather conditions but not necessarily from temperature changes. Much of the work will be done in a machine shop type environment with high noise levels, dust, and other hazards associated with machining work. A job is considered "inside" if the worker spends approximately 75 percent or more of the time inside.

WORK ENVIRONMENT:

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job.

· Must be able to work effectively in a dynamic and fast-paced environment, communicate well with others, effectively deal with technicians and customers, and accept constructive criticism. 

· Must be able to change activity frequently and cope with interruptions.