AM Materials & Process (M&P) Engineer

GM Performance Power Units; Concord (NC); On-site; USD 85,000 - 105,000; Full time

Job summary

GM Performance Power Units in Concord, NC is seeking an Additive Manufacturing Materials & Process Engineer onsite. The role combines material science with process engineering to develop, qualify, and optimize metal AM workflows from feedstock to heat treatment.

You will validate materials, analyze data, and lead data-driven continuous improvement efforts to deliver high-performance, repeatable parts.

Qualifications

• Bachelor’s or Master’s in Materials Science, Mechanical, or Manufacturing Engineering.
• 2+ years in metal additive manufacturing (LPBF preferred).
• Strong knowledge of powder metallurgy, heat treatment, and AM process development.
• Proficiency with DOE, SPC, and data analytics tools (Minitab, JMP, or Python).
• Familiarity with AS9100 / Nadcap, PFMEA, and QMS documentation.
• Skilled in AM software such as 3DXpert, Dyndrite, or Materialise Magics.

Responsibilities

• Develop and optimize part routings & AM build files for repeatable AM workflows via internal ERP/MES.
• Define, validate & optimize LBPF process & material specifications for cost-effective, repeatable AM.
• Design and execute lean DOEs to optimize laser processing and heat treatments for speed and performance.
• Develop and execute witness coupon and feedstock test plans for material and process validation.
• Perform robust DOEs to assess process variables on powder lifecycle, HT and material properties.
• Oversee powder lifecycle management, sampling, reuse strategy & contamination control.
• Define machine & part qualification plans to characterize materials for complex geometries.
• Maintain SPC and data analysis to track performance trends across Machine, Powder & Material.

Skills

Metal AM (LPBF)

DOE

SPC

Data analytics

Education

Bachelor’s or Master’s in Materials Science, Mechanical, or Manufacturing Engineering

Tools

3DXpert

Dyndrite

Materialise Magics

Job description

GM Performance Power Units - Concord, NC

AM Materials & Process (M&P) Engineer - Onsite

Job Summary

GM Performance Power Units is seeking a multidisciplinary Additive Manufacturing Materials & Process Engineer to drive the development, qualification, and optimization of metal additive manufacturing workflows. This integrated role unites material science and process engineering - ensuring every stage, from powder feedstock to heat-treated component, is engineered for performance, repeatability, and speed. The engineer will be responsible for defining parameters, validating materials, analyzing data, and leading data-driven continuous improvement activities that deliver championship-caliber parts.

Key Responsibilities

• Develop and optimize part routings & AM build files to enable efficient and repeatable AM manufacturing workflows through internal ERP/MES system
• Define, validate & optimize LBPF process & material specifications to drive cost effective yet consistent & repeatable AM processes.
• Design and execute lean DOEs to optimize laser processing parameters and heat treatments, prioritizing speed, cost efficiency, and actionable outcomes that maximize performance.
• Develop and execute witness coupon and feedstock test plans that validate both material performance and process stability.
• Perform robust DOE’s to assess the effect of key process variables on both powder lifecycle, HT and material characteristics.
• Oversee powder lifecycle management, sampling, reuse strategy & contamination control plan
• Partner with team members to define both machine & part qualification plans to characterize material of unique part geometries to ensure reliability and repeatability.
• Maintain statistical process control (SPC) and data analysis to track performance trends and drive continuous improvement across the full value chain (Machine, Powder & Material)
• Develop, maintain & integrate IoT-based monitoring, sensor feedback, and MES data collection into a centralized database.
• Support PFMEA creation, control plan development, and QMS documentation.
• Partner closely with AM Design, AM Operations, and Quality Engineering to ensure manufacturability, repeatability, and throughput.

Required Qualifications

• Bachelor’s or Master’s degree in Materials Science, Mechanical, or Manufacturing Engineering.
• 2+ years of experience in metal additive manufacturing (LPBF preferred).
• Strong knowledge of powder metallurgy, heat treatment, and AM process development.
• Proficiency in DOE, SPC, and data analytics tools (Minitab, JMP, or Python).
• Familiarity with AS9100 / Nadcap, PFMEA, and QMS documentation.
• Skilled in AM software such as 3DXpert, Dyndrite, or Materialise Magics.

KPI’s

• Parameter and material qualification lead-time reduction.
• Enabling design freedom without compromising part quality or process cost.
• First-pass yield, density, and mechanical property conformance.
• Scrap and rework cost reduction.
• Stable powder reuse and lot traceability performance.