Controls Engineer - Weekday Day Shift

VulcanForms Inc.; Ayer (MA); On-site; USD 84,800 - 116,600; Full time

Benefits offered by this job

Equity package

Medical, dental, vision insurance

401(k) with company match

Generous PTO

Job summary

VulcanForms seeks a Controls Engineer to provide onsite controls expertise during manufacturing. You will troubleshoot downtime on large industrial 3D printers and collaborate with mechanical, electrical, software, and operations teams to drive faster, more efficient resolutions.

The role supports a 24/7/365 operation with a Monday–Wednesday shift and every other Thursday, and involves ongoing documentation and process improvement efforts.

Qualifications

• 3+ years designing, developing, commissioning, and troubleshooting hardware and software for industrial control systems.
• Bachelor’s degree in Electrical, Mechanical, or Robotics Engineering or equivalent hands‑on experience.
• Proficiency with motion control, industrial safety, HMIs, process monitoring, and industrial networking.
• Ability to read PLC code and electrical schematics; read IEC 61131‑3 languages.

Responsibilities

• Monitor system performance and health to proactively identify issues before they impact production.
• Troubleshoot and resolve technical issues in fast-paced production environments with minimal downtime.
• Conduct root cause analysis to investigate recurring problems and implement preventive measures.
• Maintain accurate records of downtime, incidents, and corrective actions for continuous improvement.
• Collaborate with Engineering and Operations to ensure effective communication and alignment on process improvements.

Skills

Industrial controls

Motion control

IEC 61131-3

Electrical schematics

PLC programming

Beckhoff

TwinCAT

Industrial networking

HMI interfaces

Education

Bachelor’s degree in Electrical, Mechanical, or Robotics Engineering

Tools

Beckhoff

B&R

TwinCAT

Ethernet/IP

Job description

About Us

Founded in 2015 to develop the world’s first industrially scalable laser metal additive manufacturing solution, VulcanForms is reshaping how the world manufactures critical products. We build and operate advanced digital infrastructure that enables innovation, accelerates growth, and supports sustainability across aerospace, defense, medical, and other essential industries. Through our vertically integrated capabilities, including scalable additive manufacturing and precision machining, we deliver true end-to-end production at scale by combining cutting‑edge technology with a foundation of proven industrial craftsmanship. Our team brings deep expertise in manufacturing, materials science, software, automation, and operations, united by a shared commitment to quality, curiosity, and accountability. We foster an inclusive culture where people take ownership, solve meaningful problems, and continuously learn, because we believe diverse perspectives lead to better outcomes.

Job Purpose

As a Controls Engineer, you’ll be responsible for providing onsite controls expertise during manufacturing production. VulcanForms’ production process involves the operation of large industrial‑sized 3D printers. As a Controls Engineer, you will be involved in troubleshooting and problem solving any downtime that occurs in the production process. Working closely with mechanical, electrical, software, and operations teams, you’ll drive improvements that enable faster, more efficient resolution of production issues. VulcanForms is a 24/7/365 operation.

This shift covers Monday‑Wednesday, and every other Thursday.

Key Responsibilities

• Monitor system performance and health to proactively identify, assess, and elevate potential issues before they impact production operations.
• Troubleshoot and resolve technical issues in fast‑paced production environments, ensuring minimal disruption and timely restoration of service.
• Conduct root cause analysis (RCA) to investigate recurring problems, identify underlying causes, and assist in implementing preventive measures to avoid future incidents.
• Maintain accurate records and documentation of system downtime, incidents, and corrective actions to support continuous improvement across engineering and process teams.
• Collaborate cross‑functionally with Engineering and Operations to ensure effective communication, seamless issue resolution, and alignment on process improvements.

Qualifications

• 3+ years of experience in designing, developing, commissioning, and troubleshooting hardware and software for industrial control systems
• Bachelor’s degree in Electrical, Mechanical, or Robotics Engineering – or equivalent hands‑on experience
• Proficiency with modern control systems, including motion control (single‑ and multi‑axis), industrial safety systems, HMIs, process monitoring, and industrial networking
• Understanding of Networking in an Industrial Controls setting, Industrial Controls Safety requirements, Industrial Fieldbus Networks such as Powerlink, TwinCat, Ethernet/IP, 24v DC and AC Electrical Systems, High Voltage Drives and Motor Systems, and Industrial Sensing Solutions
• Demonstrated proficiency in at least three IEC 61131‑3 programming languages (preferably Structured Text and Sequential Function Chart)
• Ability to read and troubleshoot PLC code and read and interpret electrical schematics
• Hands‑on experience with automation platforms like B&R (preferred), Beckhoff, or similar

Preferred

• Experience with additive manufacturing (e.g., Powder Bed Fusion (PBF), Directed Energy Deposition (DED), or Direct Metal Laser Sintering (DMLS)).
• Comfortable using version control software like GitHub in multi‑developer environments.
• Experience with a wide range of industrial sensors and actuators, and the ability to recommend/select components for specific applications.
• Demonstrated experience tuning closed‑loop systems to control variables such as position, pressure, flow, and temperature.
• Strong documentation skills, including root cause analysis, software design specs, and Engineering Change Orders (ECOs).
• Familiarity with Quality Management Systems (QMS) and commissioning‑related protocols such as FAT, SACT, IQ, and MMP.

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match. The annual base salary range for this position is $84,800 to $116,600.