Sr. Metal Additive Process Engineer

Job Description

Job Description

Title: Sr. Metal Additive Process Engineer

Location: Irvine, CA

Duration: 6 Months possible extension.

Position Summary:
Lead the development, optimization, and scale-up of metal additive manufacturing (metal 3D printing) processes through hands-on operation of metal printing equipment, experimental design, and data analytics. Drive process understanding, establish robust manufacturing windows, and qualify parts and components.

Key Responsibilities:

• Operate, maintain, and optimize metal additive manufacturing systems.
• Develop and refine print parameters to improve build quality, productivity, and yield.
• Design and execute DOE studies to identify and optimize critical process parameters.
• Troubleshoot printing, powder handling, and post-processing issues using engineering and statistical methods.
• Support equipment and part qualification, process validation, and scale-up into production.

Must-Have Skills:

• Hands-on experience with metal additive manufacturing technologies.
• Strong understanding of metal powder behavior, melt pool dynamics, process parameter development, and defect mechanisms.
• Experience designing and executing DOE studies and applying statistical analysis.
• Strong troubleshooting and root-cause investigation skills.

Nice-to-Have Skills:

• Machine learning, AI, or predictive modeling for process optimization.
• Design for Additive Manufacturing (DfAM).
• Thermal modeling, FEA, or simulation of metal AM processes.

Preferred Qualifications:

• BS/MS in Mechanical Engineering, Materials Science, Manufacturing Engineering, or related discipline.
• 5+ years minimum of experience in metal additive manufacturing process development. (7-10 years' experience would be preferred).