Metal AM Materials & Process Engineer

GM Performance Power Units; Concord (NC); On-site; USD 90,000 - 130,000; Full time

Benefits offered by this job

Bonus scheme

Private healthcare

401(k) plan including company match

Life insurance

32 days annual leave

On-site gym

EV charging

Job summary

GM Performance Power Units in Concord, NC seeks an multidisciplinary Additive Manufacturing Materials & Process Engineer to drive development, qualification, and optimization of metal AM workflows from powder to heat-treated parts.

The role unites material science and process engineering to ensure performance, repeatability, and speed, with responsibility for parameter definition, material validation, data analysis, and continuous improvement initiatives across the value chain.

Qualifications

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

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.

Skills

Materials science

Mechanical engineering

Manufacturing engineering

Metal AM

DOE

SPC

Data analytics

AS9100

PFMEA

AM software

Education

Bachelors in Materials Science

Masters in Engineering

Tools

3DXpert

Dyndrite

Materialise Magics

Job description

GM Performance Power Units in Concord, NC seeks an multidisciplinary Additive Manufacturing Materials & Process Engineer to drive development, qualification, and optimization of metal AM workflows from powder to heat-treated parts.

The role unites material science and process engineering to ensure performance, repeatability, and speed, with responsibility for parameter definition, material validation, data analysis, and continuous improvement initiatives across the value chain.