Additive Manufacturing Engineer

Kensington360; Coldwater (MI); On-site; USD 85,000 - 125,000; Full time

Job summary

Kensington360 is seeking an Additive Manufacturing Engineer with hands-on LPBF experience to lead R&D process development and material qualification. You will own development from experimental builds through process optimization, collaborating with materials, production, and engineering teams to transfer validated processes into manufacturing.

Responsibilities include planning DOE-based experiments, evaluating build quality and material properties, investigating defects, and advancing

Qualifications

• Bachelor's degree in a related field required.
• 3+ years in metal additive manufacturing with LPBF experience.
• Experience developing LPBF parameters and conducting DOE.
• Understanding of powder-based manufacturing and material characterization.
• HIP and/or vacuum heat treatment experience is desirable.
• Strong analytical, documentation, and communication skills.

Responsibilities

• Develop and optimize LPBF parameters using DOE, SPC, and statistical analysis.
• Plan and execute experimental builds; evaluate build quality and material properties.
• Investigate defects, process failures, and material-performance issues.
• Support powder/feedstock development including characterization, reuse, and recycling.
• Develop and evaluate heat-treatment, HIP, and post-processing routes.
• Operate and troubleshoot R&D LPBF equipment and manage build parameters and plans.
• Analyze process and material data; translate findings into robust manufacturing processes.
• Prepare technical and qualification documentation for technology transfer to production.

Skills

LPBF experience

DOE

Statistical analysis

Process optimization

Material characterization

Troubleshooting

Documentation

Communication

Education

Bachelor's degree in Materials Science, Metallurgy, Mechanical Engineering, Aerospace Engineering, or related discipline

Job description

Additive Manufacturing Engineer – LPBF Process Development

Our client is an established advanced manufacturing and materials technology company developing high-performance metal materials and components for technically demanding applications.

The Role

We are seeking an Additive Manufacturing Engineer with hands-on Laser Powder Bed Fusion (LPBF) experience to lead R&D process development and material qualification.

You will own development activities from experimental builds through process optimization and qualification, working closely with materials, production, and engineering teams to transfer validated processes into manufacturing.

Key Responsibilities

• Develop and optimize LPBF parameters using DOE, SPC, and statistical analysis.
• Plan and execute experimental builds and evaluate build quality, material properties, repeatability, and process stability.
• Investigate defects, process failures, and material-performance issues.
• Support powder/feedstock development, including characterization, qualification, reuse, and recycling.
• Develop and evaluate heat-treatment, HIP, and post-processing routes.
• Operate and troubleshoot R&D LPBF equipment and manage build parameters, layouts, and experimental plans.
• Analyze process and material data and convert findings into robust manufacturing processes.
• Prepare technical and qualification documentation and support technology transfer into production.

Requirements

• Bachelor’s degree in Materials Science, Metallurgy, Mechanical Engineering, Aerospace Engineering, or related discipline.
• 3+ years’ experience in metal additive manufacturing, with strong hands-on LPBF experience.
• Experience developing and optimizing LPBF process parameters and conducting DOE.
• Understanding of powder-based manufacturing, material characterization, and process qualification.
• Experience with HIP and/or vacuum heat treatment is highly desirable.
• Strong equipment troubleshooting, analytical, documentation, and communication skills.
• Experience working within quality-controlled or regulated engineering environments is advantageous.