Additive Manufacturing Engineer

Leidos; United States; On-site; USD 87,100 - 157,450; Full time

Benefits offered by this job

Health and Wellness programs

Income Protection

Paid Leave and Retirement

Job summary

Leidos Defense Systems in Huntsville, AL seeks an Additive Manufacturing Engineer to join the Advanced Materials Department. The team provides materials engineering support for R&D, prototype development, and manufacturing tasks across multiple metal AM technologies.

The role emphasizes DfAM, process development, and cross‑functional collaboration to enable design through production, with a focus on high‑strength alloys and advanced materials.

Qualifications

• Hands-on experience with metal additive manufacturing engineering.
• Experience with design for additive manufacturing (DfAM) for metal processes.
• Ability to support hardware systems including AM equipment setup and troubleshooting.

Responsibilities

• Design for additive manufacturing (DfAM).
• Develop plans and layouts for additive manufacturing equipment and capabilities.
• Serve as resident additive manufacturing expert across multiple metal AM technologies.
• Perform AM analyses including cost, feasibility, deformation, and material properties.

Skills

Metal AM engineering

DfAM

AM equipment operation

Education

ABET-accredited degree in mechanical engineering/materials science

Tools

Materialise Magics

Oqton 3DXpert

EOSPrint

CAD: SolidWorks/ Creo

Job description

Description

Looking for an opportunity to make an impact?

At Leidos, we deliver innovative solutions through the efforts of our diverse and talented people who are dedicated to our customers' success. We empower our teams, contribute to our communities, and operate sustainable. Everything we do is built on a commitment to do the right thing for our customers, our people, and our community. Our Mission, Vision, and Values guide the way we do business.

Your greatest work is ahead!

Leidos' Defense Systems is seeking a 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.

If this sounds like the kind of environment where you can thrive, keep reading!

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 Responsibilities

• Design for additive manufacturing (DfAM)
• Developing plans and layouts for additive manufacturing equipment and capabilities
• Contributing to multiple program teams as the resident additive manufacturing expert across multiple metal additive technologies
• Performing additive manufacturing analyses including cost, feasibility, deformation, expected material/component mechanical and thermal properties

Basic Qualifications

• Resident of North Alabama or willing to relocate to work on-site in Huntsville, AL.
• Hands-on experience with metal additive manufacturing engineering
• Experience 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 Qualifications

• Hands-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 inspection
• Experience in communicating with external vendors or in contract manufacturing
• Experience obtaining quotes for work and equipment
• Experience writing proposals
• Design experience on Solidsworks, Creo, or other CAD systems
• Experience troubleshooting and maintaining complex AM equipment, including laser optics, process monitoring
• Experience working with hazardous materials
• Experience writing standard operating procedures and safety work practices documents
• Experience setting up AM equipment and training others on equipment

If you're looking for comfort, keep scrolling. At Leidos, we outthink, outbuild, and outpace the status quo - because the mission demands it. We're not hiring followers. We're recruiting the ones who disrupt, provoke, and refuse to fail. Step 10 is ancient history. We're already at step 30 - and moving faster than anyone else dares.

Original Posting

July 24, 2026

For U.S. Positions: While subject to change based on business needs, Leidos reasonably anticipates that this job requisition will remain open for at least 3 days with an anticipated close date of no earlier than 3 days after the original posting date as listed above.

Pay Range

Pay Range $87,100.00 - $157,450.00

About Leidos

Leidos is an industry and technology leader serving government and commercial customers with smarter, more efficient digital and mission innovations. Headquartered in Reston, Virginia, with 47,000 global employees, Leidos reported annual revenues of approximately $16.7 billion for the fiscal year ended January 3, 2025. For more information, visit www.Leidos.com .

Pay and Benefits

• competitive compensation
• Health and Wellness programs
• Income Protection
• Paid Leave and Retirement

More details are available at www.leidos.com/careers/pay-benefits .

Securing Your Data

Beware of fake employment opportunities using Leidos' name. Leidos will never ask you to provide payment-related information during any part of the employment application process (i.e., ask you for money), nor will Leidos ever advance money as part of the hiring process (i.e., send you a check or money order before doing any work). Further, Leidos will only communicate with you through emails that are generated by the Leidos.com automated system - never from free commercial services (e.g., Gmail, Yahoo, Hotmail) or via WhatsApp, Telegram, etc. If you received an email purporting to be from Leidos that asks for payment-related information or any other personal information (e.g., about you or your previous employer), and you are concerned about its legitimacy, please make us aware immediately by emailing us at [e-mail] .

If you believe you are the victim of a scam, contact your local law enforcement and report the incident to the U.S. Federal Trade Commission .

Commitment to Non-Discrimination

All qualified applicants will receive consideration for employment without regard to sex, race, ethnicity, age, national origin, citizenship, religion, physical or mental disability, medical condition, genetic information, pregnancy, family structure, marital status, ancestry, domestic partner status, sexual orientation, gender identity or expression, veteran or military status, or any other basis prohibited by law. Leidos will also consider for employment qualified applicants with criminal histories consistent with relevant laws.