Materials Engineer, Additive Manufacturing

United States Digital Space LLC; Hawthorne (CA); On-site; USD 100,000 - 140,000; Full time

Benefits offered by this job

Stock options

Long-term incentives

Medical, vision, dental coverage

Paid vacation and holidays

Job summary

United States Digital Space LLC is seeking a Materials Engineer for additive manufacturing in propulsion. The role focuses on LPBF process development for nickel-based superalloys used in next-generation rocket engines, with daily collaboration with design and manufacturing teams.

You will develop material properties, lead testing and qualification activities, and contribute to design reviews and process improvements for high-performance components.

Qualifications

• Bachelor’s degree in materials engineering or related field.
• 1+ years of experience developing or qualifying LPBF processes for nickel-based superalloys.

Responsibilities

• Provide materials and process support for propulsion system designs.
• Develop physical, mechanical, and thermal properties for materials.
• Perform root cause investigations using fractography and metallography.
• Collaborate with engineers to solve material and processing challenges.
• Work daily with additive engineering and manufacturing teams.

Skills

LPBF process development

Metallurgical testing

Fractography

Materials characterization

Education

Bachelor’s degree in materials engineering

Master’s or PhD preferred

Tools

SEM

Job description

the company was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today the company is actively developing the technologies to make this possible, with the ultimate goal ofenabling human life on Mars.

MATERIALS ENGINEER, ADDITIVE MANUFACTURING

Our Propulsion Materials team is responsible for developing and qualifying laser powder bed fusion (LPBF) processes for nickel-based superalloys used in next-generation rocket engines. In this role you will own process development, parameter optimization, and material characterization for high-performance components on Raptor engines. You will work daily with design and manufacturing teams to push the limits of what is possible with LPBF nickel superalloys and other materials. If you have significant hands‑on experience developing and qualifying LPBF processes for nickel-based superalloys and want to apply that expertise to the most demanding propulsion applications, this is the role for you.

RESPONSIBILITIES:

• Provide materials and process support for propulsion system designs and manufacturing
• Increase reliability of internal designs and manufacturing processes through material and process development
• Develop physical, mechanical, and thermal properties for materials
• Improve our additive processes and materials through characterization and development, with a primary focus on laser powder bed fusion of nickel-based superalloys
• Work directly with our additive engineering and manufacturing teams daily
• Perform root cause investigations using fractography, metallography, and testing
• Provide technical reviews and advice for design efforts specifically related to drawings, specifications, and material requirements
• Collaborate with other engineers, subject matter experts, and technicians to solve complex material and processing challenges on our current and next‑generation vehicles

BASIC QUALIFICATIONS:

• Bachelor’s degree in materials engineering or other engineering discipline with emphasis on materials
• 1+ years of professional work experience developing or qualifying laser powder bed fusion processes for nickel-based superalloys (e.g., Inconel 718, 625)

PREFERRED SKILLS AND EXPERIENCE:

• Master’s degree or PhD in materials engineering or related field
• 3+ years of professional work experience developing or qualifying laser powder bed fusion processes for nickel-based superalloys (e.g., Inconel 718, 625)
• Direct experience with LPBF parameter development, build optimization, and post-processing (HIP, heat treatment, surface finishing)
• Experience with metallurgical characterization and mechanical testing of additively manufactured nickel alloys
• Experience with one or more of the following manufacturing methods: additive (laser powder bed fusion), direct energy deposition (DED), casting, forging, brazing, heat treating
• Understanding of mechanical testing methods for metals including fracture and fatigue
• Familiarity with standard testing methods for materials and development of design allowables
• Experience with failure analysis and fractography including characterization techniques such as Scanning Electron Microscopy (SEM) and metallographic analysis
• Knowledge of aerospace metals including nickel-based alloys, stainless steels, aluminum alloys, and titanium alloys
• Hands‑on experience in a manufacturing environment
• Understanding of non‑destructive test methods for fracture control
• Proven track record developing design allowables or material specifications for LPBF nickel alloys
• Experience with fracture mechanics, fatigue, and creep testing of additively manufactured superalloys
• Hands‑on experience with process monitoring, in‑situ sensors, or advanced process control for LPBF

ADDITIONAL REQUIREMENTS:

• Extended hours and weekend work may be required to support critical project and mission milestones
• Up to 10% domestic travel is expected

COMPENSATION AND BENEFITS:

Pay Range:
Level 1: $100,000.00 - $117,500.00
Level 2: $115,000.00 - $140,000.00

Your actual level and base salary will be determined on a case‑by‑case basis and may vary based on the following considerations: job‑related knowledge and skills, education, and experience.

Base salary is just one part of your total rewards package at the company. You may also be eligible for long‑term incentives, in the form of company stock or long‑term cash awards, as well as potential discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan. You will also receive access to comprehensive medical, vision, and dental coverage, access to a 401(k) retirement plan, short and long‑term disability insurance, life insurance, paid parental leave, and various other discounts and perks. You may also accrue 3 weeks of paid vacation and will be eligible for 10 or more paid holidays per year. Employees accrue paid sick leave pursuant to Company policy which satisfies or exceeds the accrual, carryover, and use requirements of the law.

ITAR REQUIREMENTS:

• To conform to U.S. Government export regulations, applicant m