Additive Manufacturing Engineering Manager

Clark Schaefer Hackett; Falls Church (VA); On-site; USD 100,000 - 140,000; Full time

Job summary

Formative 3D in Falls Church, VA seeks an Additive Manufacturing Engineering Manager to lead LFAM/FDM operations and build a high-performance team. You will guide strategy, optimize print processes, and scale capabilities across the facility to deliver quality parts at speed.

You’ll drive automation, toolpaths, and material handling while collaborating with engineering and production to ensure continuous improvement and successful execution of smart factory initiatives.

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field.
• 7–10+ years of manufacturing experience with hands-on additive manufacturing.
• Expertise in extrusion-based printing including toolpaths and material handling.
• Experience with large-format additive systems (CEAD, Caracol, Thermwood) preferred.
• Knowledge of automation, robotics and smart factory systems (MES, ERP, IoT).
• Lean, Six Sigma or similar experience driving yield improvement and cycle time efficiency.
• Proven ability to lead technical teams in fast-paced or startup environments.

Responsibilities

• Lead and develop a team of LFAM/FDM technicians.
• Own print processes and optimization including parameters and material handling.
• Troubleshoot production issues and implement corrective actions quickly.
• Partner with Production to streamline post-processing and assembly workflows.
• Manage capacity planning, scheduling, and staffing in coordination with HR.
• Collaborate with Engineering and R&D on new materials, processes, and finishing methods.
• Drive automation and smart factory initiatives across the facility.
• Report to leadership on KPIs, timelines, resource use, and risks.
• Establish and maintain SOPs, ensuring quality, safety, and accurate documentation.
• Coach and develop team members through performance management and career growth planning.

Skills

LFAM

FDM

Toolpaths

Process optimization

Automation

Robotics

Leadership

Education

Mechanical Engineering

Mechatronics

Electrical Engineering

Materials Science

Tools

MES

ERP

IoT

Job description

Job Opportunity: Additive Manufacturing Engineering Manager with Formative 3D in Falls Church, VA

Are you a hands‑on leader with deep expertise in large‑format additive manufacturing and extrusion‑based processes? Do you enjoy building teams, optimizing production systems, and solving complex print challenges in real time? Are you excited to help scale a cutting‑edge 3D printing operation and shape the future of manufacturing? If you answered yes, we want to speak with you!

As the Additive Manufacturing Engineering Manager, you will lead both the strategic direction and day‑to‑day execution of our additive manufacturing operations. This role blends leadership, technical expertise, and operational ownership—guiding production while advancing the next generation of processes, systems, and capabilities. You'll work closely across engineering, production, and leadership teams to ensure efficient, scalable manufacturing while driving continuous improvement.

Salary range: $100k - $140k; depending on knowledge and experience.

Key Responsibilities

• Lead and develop a team of LFAM/FDM technicians, promoting safety, accountability, and continuous improvement.
• Own print processes and optimization, including parameters, material flow, toolpaths, and part quality.
• Troubleshoot production issues (e.g., delamination, warping, equipment faults) and implement corrective actions quickly.
• Partner with Production to streamline post‑processing and assembly workflows.
• Manage capacity planning, scheduling, and staffing in coordination with HR.
• Collaborate with Engineering and R&D on new materials, processes, and finishing methods.
• Drive automation and smart factory initiatives across the facility.
• Report to leadership on KPIs, timelines, resource use, and risks.
• Establish and maintain SOPs, ensuring quality, safety, and accurate documentation.
• Coach and develop team members through performance management and career growth planning.

Qualifications

• Bachelor's degree in Mechanical Engineering, Mechatronics, Electrical Engineering, Materials Science, or related field.
• 7-10+ years of manufacturing experience, including hands‑on additive manufacturing (LFAM and/or FDM).
• Expertise in extrusion‑based printing, including toolpaths, parameter optimization, and pellet/filament material handling.
• Experience with large‑format additive systems (e.g., CEAD, Caracol, Thermwood) preferred.
• Knowledge of automation, robotics, and smart factory systems (MES, ERP, IoT).
• Lean, Six Sigma, or similar experience driving yield improvement, scrap reduction, and cycle time efficiency.Proven ability to lead technical teams in fast‑paced or startup environments.
• Strong leadership, problem‑solving, and communication skills.
• Ability to work in an industrial environment and use PPE as required.

Why Join Formative 3D?

Built environments can be manufactured the same way the best technology products are: faster, smarter and at scale.

Formative 3D deploys full‑scale manufacturing solutions built for speed, flexibility and real‑world impact. By combining advanced 3D printing, robotics and technology, we rethink how physical products for the built world are created — from concept to installation. We design and manufacture products that range from high‑end furniture systems and architectural lighting to jigs, fixtures, and tooling.

Formative 3D pushes additive manufacturing forward and sets a new standard for how the built environment gets made. After years of research, our first production facility launched in 2026, and we’re already proving that a new model of manufacturing isn’t theoretical; it’s operational.

Formative 3D is an Equal Opportunity Employer. We are committed to hiring and developing the most qualified individuals based on job‑related experience, skills, and merit. All employment decisions are made without regard to race, color, religion, sex, national origin, age, disability, veteran status, or any other protected characteristic. We value a respectful, inclusive workplace where everyone has the opportunity to succeed. Formative 3D maintains a drug‑free workplace consistent with applicable local, state, and federal laws.

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