Additive Manufacturing Engineer

Additive Manufacturing EngineerLeidos' Defense Systems is seeking an Additive Manufacturing Engineer to join our team supporting the Advanced Materials Department. The Advanced Materials Department is a multi-disciplinary team that provides materials engineering expertise for every phase of a program. With backgrounds in materials science, chemistry/chemical engineering, physics, among others, the department has experience in executing a variety of efforts from R&D, to prototype development, to supporting design and build tasks for manufacturing. Beyond subject matter expertise, the department has the analysis equipment, multi-physics modelling capability and experimental lab space to support activities ranging from proof-of-concept experimentation to manufacturing support.Leidos Defense Systems Sector provides a diverse portfolio of systems, solutions, and services covering land, sea, air, space, and cyberspace for customers worldwide. Solutions for Defense include enterprise and mission IT, large-scale intelligence systems, command and control, geospatial and data analytics, cybersecurity, logistics, training, and intelligence analysis and operations support. Our team is solving the world's toughest security challenges for customers with "can't fail" missions.Primary ResponsibilitiesAs an integral member of the Advanced Materials Department, the successful candidate will balance multiple activities including but not limited to:Design for additive manufacturing (DfAM)Developing plans and layouts for additive manufacturing equipment and capabilitiesContributing to multiple program teams as the resident additive manufacturing expert across multiple metal additive technologiesPerforming additive manufacturing analyses including cost, feasibility, deformation, expected material/component mechanical and thermal propertiesBasic QualificationsResident of North Alabama or willing to relocate to work on-site in Huntsville, AL.Hands-on experience with metal additive manufacturing engineeringExperience with and basic understanding of design for additive manufacturing (DfAM), especially with Powder Bed Fusion, DED, and/or Cold Spray.Experience with metal additive manufacturing support structure design.Experience setting up metal builds with software like Materialise Magics, Oqton 3DXpert, EOSPrint, etc.Ability to support hardware systems including setup, operation, and troubleshooting of AM equipment.Familiar with high strength/temperature metal alloys (nickels, HEAs, refractories, etc.)Bachelor's degree with a minimum 3.2 GPA in mechanical engineering, materials science, manufacturing engineering, or a related field from an ABET accredited university. 4 additional years of experience required in lieu of bachelors degree.4+ years experience in metal additive manufacturing, or MS with 2+ years experience, or PhD with 1+ years experience (8 total minimum years of experience without a college degree)Preferred QualificationsHands-on experience with the following metal additive manufacturing processes: Laser Powder Bed Fusion (LPBF), Cold Spray Additive Manufacturing, Directed Energy Deposition (DED), and Wire Arc Additive Manufacturing (WAAM)Experience with build parameter development, process development/optimization, and qualification.Familiarity with post-processing methods including heat treatment, machining, and surface finishing.Experience with simulation tools for additive manufacturing (thermal, distortion, support optimization).Exposure to in-situ monitoring systems or sensor integration in AM platforms.Programming or scripting experience (Python, MATLAB, or similar) for data analysis or workflow automation.Hands on experience preparing mechanical testing, including monotonic, fatigue, creep, etc.Experience with metallurgical specimen preparation and inspectionExperience in communicating with external vendors or in contract manufacturingExperience obtaining quotes for work and equipmentExperience writing proposalsDesign experience on Solidsworks, Creo, or other CAD systemsExperience troubleshooting and maintaining complex AM equipment, including laser optics, process monitoringExperience working with hazardous materialsExperience writing standard operating procedures and safety work practices documentsExperience setting up AM equipment and training others on equipment