Senior Simulation Engineer

SENIOR SIMULATION ENGINEER 

Freeform builds AI-native manufacturing systems that unify software, hardware, and physics to produce industrial-scale parts at the speed of human ideation. By treating manufacturing as a single integrated system, we unlock a new era of innovation where complex hardware is designed, built, and scaled without limits.

As a Simulation Engineer at Freeform, you will be responsible for developing physics-based, data-driven models that enable the first production scale, high quality, and fully automated metal 3D printing factory capability. We are looking for someone with deep knowledge in physical simulations and multi-physics phenomena who can develop sophisticated models from scratch for undefined or previously unsolved problem statements. This person needs to be comfortable working in an interdisciplinary environment that iterates quickly and decisively.

3D printing experience is not required to be successful here - rather we look for smart, motivated, collaborative engineers who love solving hard problems and creating amazing technology!

Responsibilities: 

• Develop high-performance numerical solvers for simulating the physics of advanced metal 3D printing systems
• Implement numerical simulation models for real-time or near-real-time performance on HPC or GPU platforms
• Work with software engineers to build and deploy physics-based and data-driven models of the laser powder bed fusion process
• Work with software engineers to integrate low-level solvers into simulation pipelines and interface with hardware systems
• Guide the integration of computational geometry and meshing techniques to support large-scale, physics-driven simulations
• Architect simulation modules for execution on specialized compute hardware including FPGAs and GPUs
• Contribute to the development of model-predictive control strategies alongside control engineers
• Generate and maintain documentation for all algorithms, solvers, and integrated systems

Basic Qualifications:

• Bachelor’s degree in applied mathematics, physics, computer science, mechanical engineering, or a related technical field
• 5+ years of professional experience developing custom simulation solvers with a bachelor’s degree, 2+ years of professional experience with a master’s degree, or a PhD in one of the above fields in lieu of industry experience
• Demonstrated experience writing low-level numerical solvers for physical simulations
• Strong programming skills in C, C++, or CUDA
• Experience developing simulations in a high-performance compute environment (i.e. running on GPUs)
• Academic or professional familiarity with solid mechanics, continuum mechanics, or other physical modeling domains

Nice to Have:

• MS or PhD in applied mathematics, physics, computer science, mechanical engineering, or a related field
• Experience with real-time or near-real-time simulations on GPU or parallel computing platforms
• Experience with direct numerical simulation (DNS) models
• Familiarity with solid mechanics, continuum mechanics, or other physical modeling domains
• Experience with thermo-elastic or thermo-elastoplastic modeling
• Familiarity with computational geometry and meshing techniques
• Experience with data-driven modeling techniques and hybrid physics/data simulation methods
• Familiarity with optimization techniques and control theory
• Experience with 2D and 3D meshing libraries and tools
• Creative problem solver with a strong foundation in first-principles thinking and numerical analysis
• Strong written and verbal communication skills

Location:

• Based in Hawthorne, our vertically integrated facility brings technology development, R&D, and production together under one roof. We operate at the center of LA’s deep tech ecosystem, surrounded by some of the most ambitious hardware innovation happening anywhere in the country.
• Our fast-paced, cross-functional environment is built on close collaboration, and as such, this role requires full-time onsite presence (five days a week), with very limited exceptions.

What We Offer:

• We have an inclusive and diverse culture that values collaboration, learning, and making deliberate data-driven decisions.
• We offer a unique opportunity to be an early and integral member of a rapidly growing company that is scaling a world-changing technology.
• Benefits
• Significant stock option packages
• 100% employer-paid Medical, Dental, and Vision insurance (premium PPO and HMO options)
• Life insurance
• Traditional and Roth 401(k)
• Relocation assistance provided 
• Paid vacation, sick leave, and company holidays
• Generous Paid Parental Leave and extended transition back to work for the birthing parent
• Free daily catered lunch and dinner, and fully stocked kitchenette
• Casual dress, flexible work hours, and regular catered team building events
• Compensation  
• As a growing company, the salary range is intentionally wide as we determine the most appropriate package for each individual taking into consideration years of experience, educational background, and unique skills and abilities as demonstrated throughout the interview process. Our intent is to offer a salary that is commensurate for the company’s current stage of development and allows the employee to grow and develop within a role. 
• In addition to the significant stock option package, the estimated salary range for this role is $150,000-$225,000 . The upper end of the range is reserved for individuals who demonstrate exceptional experience, deep domain mastery, and a proven history of high performance and impact.
• Freeform is an Equal Opportunity Employer that values diversity; employment with Freeform is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.