NPI Engineer (Process)

VulcanForms Inc.; Ayer (MA); On-site; USD 106,500 - 146,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision

Life insurance

Paid time off

401(k)

Job summary

VulcanForms Inc. in the United States seeks a Senior Product Development Engineer to establish and optimize reliable post-processing processes. You will leverage cross-functional teams to sample and launch new products, and scale post-processing operations from post-print to finished parts.

Lead the Production Team, define requirements, coordinate with suppliers, and implement tooling solutions. You will also drive process improvements, ensure quality and regulatory compliance, and contribute to

Qualifications

• Requires a Bachelor's degree in Mechanical, Manufacturing, or Industrial Engineering.
• 5+ years in manufacturing engineering, focusing on post-processing methods like machining and finishing.
• Hands-on experience developing and scaling production processes.
• Familiar with process qualification methods and documentation.
• Knowledge of lean tools and continuous improvement.

Responsibilities

• Define and support post-processing steps for new products; convert designs into scalable processes.
• Oversee manufacturing process implementation with in-house teams and suppliers.
• Specify tooling, fixturing, and post-processing equipment requirements; drive automation opportunities.
• Create and maintain SOPs, work instructions, and process documentation.
• Lead IQ/OQ/PQ activities and support QC/QA in qualifications.
• Contribute to NPI discussions and DFfM decisions with design and production teams.
• Work with teams to set takt time, throughput, and cost estimates for new/existing products.
• Collaborate with HSSE to ensure safety and ergonomic standards in new equipment.
• Drive cost savings and scrap reduction using root-cause analysis and lean methods.

Skills

Post-processing

Manufacturing process development

Cross-functional collaboration

Documentation

Lean manufacturing

Quality/regulatory

Education

Bachelor's degree in Mechanical/Manufacturing/Industrial Engineering

Tools

PFMEA

DOE

IQ/OQ/PQ

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.

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

• The Senior Product Development Engineer will establish and optimize reliable processes, working cross‑functionally to deliver safe, efficient processes that meet quality, cost, capacity, and customer requirements. This role will work cross‑functionally on NPI teams to support process development and help successfully sample and launch new products. This role will also be responsible for taking new products from post‑print to finished product by developing and scaling robust post‑processing operations. They will provide technical leadership for the Production Team, define process requirements, coordinate with suppliers, and implement tooling and equipment solutions for post‑processing printed parts and components.

Key Responsibilities

• Define and support post‑processing steps (e.g., machining, blasting, deburring, cleaning, heat treating) for new product; turn product designs and requirements into robust, scalable manufacturing processes.
• Oversee the implementation of manufacturing processes by collaborating with in‑house technicians and external suppliers. Coordinate machine setup and process validation while maintaining technical ownership.
• Define functional requirements for tooling, fixturing, and post‑processing equipment, including identifying opportunities for automation or capital investment to improve productivity. Partner with suppliers to deliver reliable solutions, and lead their implementation, testing, and validation.
• Write and maintain detailed work instructions, standard operating procedures (SOPs), and process documentation to ensure repeatable and high‑quality production.
• Lead Installation Qualifications (IQ) for manufacturing equipment and support QC and Quality Engineering in Operational and Performance Qualifications (OQ/PQ). Help ensure all processes meet quality and regulatory requirements.
• Engage in the NPI process as required to understand part requirements and contribute to design‑for‑manufacturability (DFM) decisions. Work closely with design, quality, and production teams to align on cost, capability, and scalability.
• Collaborate with product and manufacturing teams to define takt time, throughput targets, and resource needs (equipment, labor, space) to support forecasted production volumes – including estimating manufacturing costs and time standards for new and existing products.
• Work with the HSSE team to assess risks and ensure that new equipment and processes meet internal safety and ergonomic standards.
• Drive process improvements aimed at scrap reduction and cost savings using root cause analysis, lean tools and data‑driven decision making.

Qualifications

• Bachelor’s degree in Mechanical, Manufacturing, or Industrial Engineering (or related field)
• 5+ years of experience in manufacturing engineering, with a focus on post‑processing methods (e.g., machining, blasting, fixturing)
• Hands‑on experience developing and scaling production processes
• Proficiency in process qualification tools and methods (e.g., PFMEA, DOE, IQ/OQ/PQ)
• Strong cross‑functional collaboration skills, including working with suppliers, technicians, and internal engineering, quality, and production teams
• Experience creating and maintaining process documentation (e.g., SOPs, work instructions, validation plans)
• Knowledge of Lean Manufacturing, root cause analysis, and continuous improvement methods

Preferred Qualifications

• Experience with metal additive manufacturing and transitioning printed parts to finished product
• Familiarity with post‑processing techniques, GD&T, and tooling design (hands‑on or oversight)
• Background in regulated or quality‑controlled environments (e.g., medical device, aerospace) and experience qualifying equipment or automated processes
• Exposure to ERP/MES systems, manufacturing data tools, and safety or ergonomic assessments

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience.

• Medical, dental, vision, and life insurance
• Generous paid time off
• 401(k) plan with company match

The annual base salary range for this position is $106,500 to $146,000.