Staff Product Development Engineer, Aerospace & Defense

VulcanForms Inc.; Ayer (MA); On-site; USD 125,000 - 172,000; Full time

Job summary

VulcanForms Inc. is seeking a Lead Product Development Engineer, Aerospace & Defense, to own customer products from concept to serial production.

You will lead a cross-functional engineering team to maximize value and build processes that deliver repeatable, qualified production with consistent print quality and efficient throughput. This is a senior technical role acting as the primary technical authority across hardware, software, materials, and operations to deliver production-ready parts for

Qualifications

• 8+ years hands-on experience in product or applications development, preferably in LPBF or additive technology.
• Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or related field.
• Expert-level proficiency in advanced 3D CAD software (e.g., Siemens NX, Creo, SolidWorks). Specialized build-prep tools preferred (Magics, nTopology, Amphyon).
• Deep mastery of GD&T, advanced statistical process capability, tolerance stack-up analysis, and DFM/DfAM constraints.
• Outstanding leadership and communication skills with ability to influence technical roadmaps and mentor engineering talent.
• Strong working knowledge of subtractive manufacturing operations (5-axis milling, turning, EDM) and integration with additive workflows.

Responsibilities

• Lead cross-functional team of additive, post-processing, and quality engineers to maximize customer value.
• Evaluate early-stage opportunities for feasibility and define the new product introduction path with program leads.
• Apply Design for Manufacturing (DFM) principles from the start of every program across hardware, software, materials, and operations.
• Mentor junior engineers and provide technical troubleshooting on development builds as issues surface in production.
• Support metrological solutions to meet qualification and production needs.
• Keep parts moving efficiently through the factory across production programs.
• Lead root cause investigations for complex part defects and implement CAPA via data analysis and testing.
• Oversee First Article Inspections (FAI) and production launches for the Aerospace & Defense vertical.
• Execute change orders in response to customer design changes and KPI targets.
• Identify improvements to the product development process to drive efficiency and consistency.

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 Lead Product Development Engineer, Aerospace & Defense at VulcanForms, you will own customer products from initial concept through serial production. You will lead a cross-functional engineering team to get the most out of our vertically integrated manufacturing operation, and you will build the engineering processes that turn a customer concept into a repeatable, qualified production program with consistent print quality, reliable equipment, and efficient throughput.

This is a senior technical role. You will act as the primary technical authority for your programs, working across hardware, software, materials, and operations to deliver production‑ready parts for our most strategic aerospace and defense customers.

Key Responsibilities

• Lead a cross-functional team of additive, post‑processing, and quality engineers to develop part processes that maximize customer value.
• Evaluate early‑stage opportunities for feasibility, working with senior technical staff to define the new product introduction path and with program leads to set clear expectations and keep technical development on track.
• Work with automation, machining, and finishing process owners as well as outside vendors to apply Design for Manufacturing (DFM) principles from the start of every program.
• Support junior engineers with technical troubleshooting on development builds, adjusting plans as issues surface while work in process moves through the factory.
• Support quality engineering in selection and execution of appropriate metrological solutions effectively meet customer needs from a qualification and production perspective.
• Support production programs by keeping parts moving efficiently through the factory.
• Lead root cause investigations for complex part defects and implement corrective and preventive actions (CAPA) using data analysis and iterative testing.
• Oversee the technical execution of First Article Inspections (FAI) and production launches for the A&D vertical.
• Oversee and execute change orders in response to customer design changes and internal KPI targets.
• Identify improvements to our product development process so that teams work efficiently and consistently meet customer needs.

Salary and Benefits

• 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 $124,800 to $171,600.

Qualifications

• 8+ years of progressive, hands‑on experience in product or applications development with a preference for candidates with experience in LPBF or similar additive technology.
• Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a related field.
• Expert‑level proficiency in advanced 3D CAD software (e.g., Siemens NX, Creo, SolidWorks) Specialized skills with build‑preparation tools (e.g., Magics, nTopology, Amphyon) preferred.
• Deep mastery of GD&T, advanced statistical process capability, tolerance stack‑up analysis, and complex DFM/DfAM constraints.
• Outstanding leadership and communication skills, with a proven ability to influence technical roadmaps, align multidisciplinary stakeholders, and mentor engineering talent.
• Strong working knowledge of subtractive manufacturing operations (5‑axis milling, turning, EDM) and their integration with additive workflows