Additive Manufacturing Process Engineer

Aegis - an Airsys Company; South Carolina; On-site; USD 85,000 - 125,000; Full time

Job summary

Aegis - an Airsys Company is seeking an experienced Additive Manufacturing Process Engineer to develop, optimize, validate, and support metal LPBF/SLM processes. You will focus on parameter development, complex build troubleshooting, and transferring validated processes into production.

You will lead process windows, build strategies, and defect root-cause analysis while collaborating with design, manufacturing, and quality teams to ensure robust process documentation and training.

Qualifications

• Bachelor's degree in a mechanical, materials, manufacturing, metallurgical, or related field.
• 3–5+ years of relevant engineering experience, preferably in metal additive manufacturing or advanced manufacturing.
• Hands-on experience developing and modifying LPBF/SLM process parameters, not limited to operating pre-qualified parameter sets.
• Strong understanding of laser power, scan speed, hatch spacing, layer thickness, contour parameters, scan strategy, melt pool behavior, and common AM defects.
• Experience with structured troubleshooting, root-cause analysis, process validation, and technical documentation.
• Ability to independently manage process development activities and communicate technical results across engineering, quality, and manufacturing teams.

Responsibilities

• Develop, optimize, and validate LPBF/SLM process parameters for different materials, geometries, and performance requirements.
• Provide hands-on engineering support for machine setup, build preparation, printing, troubleshooting, and complex or high-risk builds.
• Develop and qualify new metal powders, scan strategies, support strategies, and process windows.
• Lead root-cause analysis for print defects including porosity, lack of fusion, cracking, warping, delamination, recoater interference, and dimensional issues.
• Review part designs for printability, including wall thickness, internal channels, overhangs, orientation, supports, and powder removal.
• Analyze print data and test results to improve density, surface quality, dimensional accuracy, repeatability, and build success rate.
• Plan and support process validation through density testing, metallography, microscopy, dimensional inspection, surface measurement, and pressure/leak testing.
• Develop and maintain process specifications, parameter records, work instructions, validation reports, and manufacturing standards.
• Transfer validated processes from development into production and provide technical support during initial manufacturing builds.
• Support continuous improvement of machine utilization, material usage, cycle time, yield, and overall process reliability.
• Provide technical guidance and training to technicians and junior engineers.
• Support safe powder handling, equipment operation, and additive manufacturing safety requirements.

Skills

LPBF/SLM parameter development

Root-cause analysis

Troubleshooting

Data analysis

Cross-functional communication

DFAM/DOE/CPk

Education

Bachelor's degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, Metallurgical Engineering, or a related field

Tools

Materialise Magics

3DXpert

Netfabb

EOSPRINT

Siemens NX

Job description

We are seeking an experienced Additive Manufacturing Process Engineer to develop, optimize, validate, and support metal additive manufacturing processes, with a primary focus on LPBF/SLM. This role requires strong hands-on experience in parameter development, complex build troubleshooting, process validation, and transfer of validated processes into regular manufacturing.

Key Responsibilities

• Develop, optimize, and validate LPBF/SLM process parameters for different materials, geometries, and performance requirements.
• Provide hands-on engineering support for machine setup, build preparation, printing, troubleshooting, and complex or high-risk builds.
• Develop and qualify new metal powders, scan strategies, support strategies, and process windows.
• Lead root-cause analysis for print defects including porosity, lack of fusion, cracking, warping, delamination, recoater interference, and dimensional issues.
• Review part designs for printability, including wall thickness, internal channels, overhangs, orientation, supports, and powder removal.
• Analyze print data and test results to improve density, surface quality, dimensional accuracy, repeatability, and build success rate.
• Plan and support process validation through density testing, metallography, microscopy, dimensional inspection, surface measurement, and pressure/leak testing.
• Develop and maintain process specifications, parameter records, work instructions, validation reports, and manufacturing standards.
• Transfer validated processes from development into production and provide technical support during initial manufacturing builds.
• Support continuous improvement of machine utilization, material usage, cycle time, yield, and overall process reliability.
• Provide technical guidance and training to technicians and junior engineers.
• Support safe powder handling, equipment operation, and additive manufacturing safety requirements.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, Metallurgical Engineering, or a related field.
• 3-5+ years of relevant engineering experience, preferably in metal additive manufacturing or advanced manufacturing.
• Hands-on experience developing and modifying LPBF/SLM process parameters, not limited to operating pre-qualified parameter sets.
• Strong understanding of laser power, scan speed, hatch spacing, layer thickness, contour parameters, scan strategy, melt pool behavior, and common AM defects.
• Experience with structured troubleshooting, root-cause analysis, process validation, and technical documentation.
• Ability to independently manage process development activities and communicate technical results across engineering, quality, and manufacturing teams.

Software & Technical Skills

• Experience with AM build preparation and slicing software such as Materialise Magics, 3DXpert, Netfabb, EOSPRINT, QuantAM, or equivalent.
• Proficiency with CAD software such as SolidWorks, Siemens NX, Creo, or equivalent.
• Experience with part orientation, support generation, slicing, build layout, and parameter configuration.
• Proficiency with Excel and experience with Minitab, JMP, MATLAB, Python, or equivalent data-analysis tools is preferred.
• Familiarity with metallography, microscopy, dimensional inspection, surface measurement, GD&T, and engineering drawings.
• Knowledge of DfAM, DOE, SPC, Cp/Cpk, 5-Why, Fishbone, and other structured problem-solving methods is preferred.
• Experience with complex AM geometries such as thin walls, internal channels, lattice structures, and TPMS structures is a plus.

Preferred Experience

• Experience with copper, copper alloys, aluminum, titanium, stainless steel, or other metal powder systems.
• Knowledge of downstream processes such as heat treatment, EDM, machining, blasting, and polishing.