Senior Applications Engineer (Metals)

Frey Consulting Group; Austin (TX); Hybrid; USD 110,000 - 130,000; Full time

Job summary

Frey Consulting Group in Austin, TX seeks a Senior Applications Engineer (Metals) to lead hands-on metal LPBF part production and act as a technical consultant for diverse partners.

You will design, print, and guide post-processing (heat treatment, wire EDM, CNC) while collaborating with clients to scope AM goals and deliver parts on schedule.

Qualifications

• 4+ years of hands-on metal LPBF experience.
• Proficiency in Magics, 3DXpert and CAD tools.
• Experience with FEA and CAM workflows.
• Knowledge of post-processing, heat treatment and wire EDM.
• Familiarity with ITAR/export-controlled projects.
• Bachelor’s degree in a related engineering field or equivalent LPBF experience.

Responsibilities

• Consult with clients to scope AM goals and develop execution plans.
• Print complex geometries and manage on-site production activities.
• Oversee post-processing steps including heat treatment and CNC machining.
• Serve as the metal LPBF subject-matter expert during customer visits and events.

Skills

LPBF experience

CAD modeling

FEA

CAM

Post-processing knowledge

ITAR / export-controlled

Physical lab readiness

Education

Bachelor’s degree in Mechanical/Aerospace/Materials/Manufacturing Engineering

Tools

Magics

3DXpert

CAD platforms

Job description

• Job Title: Senior Applications Engineer (Metals)
• Location: Austin, Texas
• Work Arrangement: Hybrid (3 days on site, 2 days remote). Ability to come on site 5 days per week if business needs dictate.
• Travel: 4 weeks per year
• Compensation: $110,000 - $130,000 base salary (DOE) + 10% bonus

Required Skills

• 4+ years of hands-on metal Laser Powder Bed Fusion (LPBF) additive manufacturing experience.
• Proficiency in CAD modeling and LPBF support generation software (e.g., Magics, 3DXpert), FEA (Finite Element Analysis), and CAM (Computer-Aided Manufacturing).
• Experience defining post-processing operations (heat treatment, wire EDM, machining).
• Ability to work on ITAR and export-controlled projects.
• Bachelor’s degree in a related engineering field (e.g. mechanical, aerospace, manufacturing, materials engineering) or equivalent experience with metal LPBF (Laser Powder Bed Fusion).
• Ability to lift 25 lbs. regularly, wear a respirator, and be on your feet throughout the day.

Preferred Skills

• Project management experience or PMP certification.

Employer Value Proposition

• Exposure to cutting-edge tools. Work for an industry leader and other manufacturing industry leaders (Aerospace, automotive, consumer electronics, defense, etc.) Broad-based industry exposure developing new applications.
• Strong tenure and opportunities for promotion (upward mobility). Work-life balance with a 40-hour work week.

Job Description

As a Senior Applications Engineer, you will act as a technical consultant and hands-on maker. You will collaborate with client partners to translate complex engineering challenges into high-performance metal LPBF parts, physically bringing those designs to life in our state-of-the-art facility.

Why This Role is Different

• Full Lifecycle Ownership: Go beyond the screen. You will design, print, and direct the post-processing of parts from start to finish.
• Diverse Industry Impact: Solve complex thermal and structural challenges for a rotating lineup of aerospace, automotive, and defense partners.
• Global Network: Join a team of over 1,000 innovators accelerating the transition to sustainable, high-efficiency production.

Your Mission

• Consult & Partner: Collaborate with clients to scope AM goals and build technical execution plans.
• Execute with Precision: Print complex geometries hands-on, utilizing deep process and materials knowledge to deliver parts on schedule.
• Oversee Post-Processing: Define and guide crucial post-print operations (heat treatment, wire EDM, CNC machining).
• Be the Technical Expert: Serve as the subject matter expert for metal LPBF, supporting customer visits and industry events.

What You Bring

• Education & Experience: BS in Mechanical, Aerospace, Materials, or Manufacturing Engineering (or equivalent experience), plus 4+ years of hands-on metal LPBF experience.
• Software Tooling: Proficiency in design and prep software (Magics, 3DXpert, and CAD platforms).
• Lab Readiness: Ability to handle physical lab environments (lifting 25 lbs., wearing respirators, active floor presence).
• Professional Skills: Strong project management skills and a collaborative, client-facing mindset.