Model Maker

ALTEN Technology USA; Foster City (CA); On-site; USD 85,000 - 100,000; Full time

Job summary

ALTEN Technology USA seeks a Model Maker to turn design intent into high-fidelity prototypes for autonomous vehicle programs. You will operate SLA, SLS, FDM and PolyJet, finish and assemble parts to meet learning objectives, collaborating daily with engineers and designers.

You will perform build prep, post-processing, inspection, and documentation while maintaining lead times and cost targets in a hands-on, team-driven environment.

Qualifications

• BS/BA in engineering or related field, or equivalent hands-on experience.
• 2-5 years of hands-on additive manufacturing, model making, or prototype fabrication.
• Working knowledge of additive processes (SLA, SLS, FDM, PolyJet) and tradeoffs between speed, strength and finish.
• Ability to read and navigate CAD (SolidWorks, CATIA or similar) and GD&T callouts.

Responsibilities

• Additive Build Execution: prepare, nest, slice and run builds on SLA, SLS, FDM and PolyJet platforms; select process/material; monitor builds and resolve failures.
• Design for Additive (DfAM) Feedback: review CAD models for printability and risks; document changes; clarify ambiguities early.
• Post-Processing & Finishing: remove supports, sanding, priming, painting, dyeing, inserts and finishing for production look.
• Model Assembly & Integration: assemble prototypes, integrate printed parts with CNC, laser-cut and purchased components.
• Inspection & Quality: verify part accuracy with calipers, micrometers; read drawings and GD&T callouts.
• Queue & Workflow Management: manage JIRA queue and deadlines; communicate status and risks.
• Machine Care: routine maintenance and vendor coordination for additive equipment.
• Documentation & Collaboration: document build parameters and safety protocols; collaborate with CNC and Welding teams.

Skills

Additive manufacturing

Model making

Reading drawings

GD&T

Precision measurement

Finishing

Education

BS/BA in engineering or related field

2-5 years hands-on additive manufacturing

Tools

SLA

SLS

FDM

PolyJet

GrabCAD Print

Materialise Magics

Autodesk Fusion AM build extensions

Job description

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more.

As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing.

When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow.

As a Model Maker, you will transform engineering and design intent into high-fidelity physical prototypes and appearance models for our autonomous vehicle programs. With an additive-led skill set, you will operate and optimize our 3D printing platforms (SLA, SLS, FDM, PolyJet), then finish, assemble and integrate those parts into models that meet the requestor’s learning objectives. You will work hands-on every day, partner directly with engineers and designers, and help the XOPS Prototype Fabrication team rapidly transform the high-impact experimental concepts into physical parts, with excellent lead times, quality and cost.

Responsibilities

• Additive Build Execution: Prepare, nest, slice and run builds on SLA, SLS, FDM and PolyJet platforms using standard build parameters; select the right process and material for each part's requirements; monitor builds and resolve failures (warping, adhesion, supports).
• Design for Additive (DfAM) Feedback: Review CAD models and flag printability and failure risks before parts reach the build tray; make and document minor model-side geometry changes; elevate drawing ambiguities early.
• Post-Processing & Finishing: Execute support removal, sanding, priming, painting, dyeing, inserts and other finishing to bring parts toward a production look and feel.
• Model Assembly & Integration: Assemble high-fidelity prototypes and appearance models, integrating printed parts with CNC-machined, laser-cut and purchased components and electronics.
• Inspection & Quality: Verify part accuracy using calipers, micrometers and other precision measurement tools; read drawings, GD&T and finish callouts well enough to build and inspect to them.
• Queue & Workflow Management: Work from the JIRA request queue, sequencing builds to meet requestor deadlines; communicate status and flag risks early.
• Machine Care: Perform routine maintenance and first-line troubleshooting on additive equipment; coordinate with vendors for service when needed.
• Documentation & Collaboration: Contribute to build-parameter and finishing documentation; follow lab safety and material-handling protocols; collaborate with CNC, Welding and other Prototype Fabrication disciplines.

Required Qualifications

• BS/BA in engineering, industrial design or a related field, or equivalent hands-on experience.
• 2-5 years of hands-on additive manufacturing, model making or prototype fabrication experience.
• Working knowledge of additive processes and materials (SLA, SLS, FDM, PolyJet) and the tradeoffs between speed, strength and finish.
• Experience with build-prep/slicing software such as GrabCAD Print (Stratasys), Materialise Magics, Autodesk Fusion (AM build extensions) or similar.
• Ability to read and navigate CAD (SolidWorks, CATIA or similar), drawings, and GD&T callouts.
• Proficiency with precision measurement tools.
• Hands-on finishing skills: sanding, priming, painting, bonding and assembly.
• Ability to manage own queue, work with light supervision, and communicate clearly with engineers and designers.

Preferred Qualifications

• Experience with surfacing or CAD authorship for printable parts and fixtures.
• Experience with paint matching, surface texturing or appearance/ergonomic models.
• Experience in other prototyping methods: CNC operation, laser cutting, MIG/TIG welding, foam, wood, urethane or clay modeling.
• Experience with OSHA-compliant shop practices or hazardous material (HazMat) handling.

Salary Range

• $85,000 - 100,000
• The actual salary offered is dependent on various factors including, but not limited to, location, the candidate’s combination of job-related knowledge, qualifications, skills, education, training, and experience

All qualified applicants will receive consideration for employment and will not be discriminated against on the basis of race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, age, genetic information, or pregnancy.

Compliance Notice

Alten USA is a federal contractor subject to the requirements of the Vietnam Era Veterans' Readjustment Assistance Act (VEVRAA) and Executive Order 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.

Drug Screening Requirement

As a federal contractor, Alten USA maintains a drug-free workplace. All candidates selected for employment will be required to successfully complete a pre-employment drug screening as a condition of hire.

Protected Veteran Information

If you believe you belong to any of the categories of protected veterans listed below, please indicate by making the appropriate selection. As a government contractor subject to the Vietnam Era Veterans Readjustment Assistance Act (VEVRAA), we request this information in order to measure the effectiveness of the outreach and positive recruitment efforts we undertake pursuant to VEVRAA. Classification of protected categories is as follows:

A 'disabled veteran' is one of the following: a veteran of the U.S. military, ground, naval or air service who is entitled to compensation (or who but for the receipt of military retired pay would be entitled to compensation) under laws administered by the Secretary of Veterans Affairs; or a person who was discharged or released from active duty because of a service-connected disability.

A 'recently separated veteran' means any veteran during the three-year period beginning on the date of such veteran's discharge or release from active duty in the U.S. military, ground, naval, or air service.

An 'active duty wartime or campaign badge veteran' means a veteran who served on active duty in the U.S. military, ground, naval or air service during a war, or in a campaign or expedition for which a campaign badge has been authorized under the laws administered by the Department of Defense.

An 'Armed forces service medal veteran' means a veteran who, while serving on active duty in the U.S. military, ground, naval or air service, participated in a United States military operation for which an Armed Forces service medal was awarded pursuant to Executive Order 12985.