Powder Metal Applications Engineer

Job Description

Job Description

Position summary

We are seeking a Powder Metal Applications Engineer to join our Advanced Technology Engineering Team and drive growth through new metal injection molding (MIM) products, applications, and markets. You will be the key technical link between our customers, the Commercial Sales Team, and the Product Launch Team.

In this role, you will plan and execute the design, development and promotion of new MIM components. You will help Sales win new business with accurate quotations and sound design guidance. You will also lead early-stage launch work so new products move smoothly through production approval and into manufacturing.

Location: Rockford, IL, USA
Salary: $100,000–$130,000 per year
Employment type: Full-time, exempt

Essential functions and responsibilities

1. Engineering quotations. Develop complete engineering quotations for new MIM components, including:
   • Raw material (feedstock) requirements
   • Operation steps, cycle times and rates
   • Outside operation costs (e.g., heat treatment, machining, plating, finishing)
   • Tooling, fixture and gauging costs
   • Capital equipment requirements and costs
2. Design for manufacturability (DFM). Review customer component designs and recommend changes that make them manufacturable with DSB's MIM technology. Produce marked-up prints and modify CAD solid models as needed to support tooling, molding, debinding and sintering.
3. Prototype and engineering samples. Lead the manufacture and on-time delivery of all engineering and prototype samples, coordinating with tooling, molding, sintering, secondary operations and quality.
4. Customer technical lead. Lead technical and engineering discussions with customers on design, materials, tolerances and cost. Act as the customer's voice in internal engineering, quality and operations discussions.
5. APQP leadership. Lead the APQP team through Gate 1 (planning and feasibility), and participate as a core team member through Gate 5 (launch and production approval), including support for PPAP and production readiness.
6. Market and application development. Identify new applications and markets for MIM, support customer presentations and trade shows, and help Sales position MIM against competing processes such as machining, casting and stamping.
7. Perform other related duties as assigned.

Requirements

• Bachelor's degree in Mechanical, Manufacturing, Materials or Metallurgical Engineering, or equivalent experience
• [5+] years as an Applications, Product or Design Engineer in metal injection molding (MIM) or powder metallurgy (PM)
• Hands-on design skills, including proficiency with 3D CAD (e.g., SolidWorks, Creo, NX) and reading and marking up engineering drawings
• Working knowledge of GD&T and tolerance analysis
• Experience building cost estimates or quotations for manufactured components
• Familiarity with APQP, PPAP and new product launch processes
• Strong communication, organization and project management skills

Preferred qualifications

• Experience across the full MIM process: feedstock, tool design, molding, debinding, sintering and secondary operations
• Knowledge of common MIM alloys (stainless steels, low-alloy steels, tool steels, soft magnetic or titanium alloys)
• Experience in regulated or high-reliability markets such as medical, automotive (IATF 16949), aerospace, firearms or consumer electronics
• Exposure to mold-flow simulation and sintering shrinkage/distortion prediction
• Six Sigma, DFMEA/PFMEA or Lean experience