Senior LPBF/SLM Additive Manufacturing Engineer

Aegis - an Airsys Company; South Carolina; On-site; USD 85,000 - 125,000; Full time

Job summary

Aegis - an Airsys Company is seeking an experienced Additive Manufacturing Process Engineer to develop, optimize, validate, and support metal LPBF/SLM processes. You will focus on parameter development, complex build troubleshooting, and transferring validated processes into production.

You will lead process windows, build strategies, and defect root-cause analysis while collaborating with design, manufacturing, and quality teams to ensure robust process documentation and training.

Qualifications

• Bachelor's degree in a mechanical, materials, manufacturing, metallurgical, or related field.
• 3–5+ years of relevant engineering experience, preferably in metal additive manufacturing or advanced manufacturing.
• Hands-on experience developing and modifying LPBF/SLM process parameters, not limited to operating pre-qualified parameter sets.
• Strong understanding of laser power, scan speed, hatch spacing, layer thickness, contour parameters, scan strategy, melt pool behavior, and common AM defects.
• Experience with structured troubleshooting, root-cause analysis, process validation, and technical documentation.
• Ability to independently manage process development activities and communicate technical results across engineering, quality, and manufacturing teams.

Responsibilities

• Develop, optimize, and validate LPBF/SLM process parameters for different materials, geometries, and performance requirements.
• Provide hands-on engineering support for machine setup, build preparation, printing, troubleshooting, and complex or high-risk builds.
• Develop and qualify new metal powders, scan strategies, support strategies, and process windows.
• Lead root-cause analysis for print defects including porosity, lack of fusion, cracking, warping, delamination, recoater interference, and dimensional issues.
• Review part designs for printability, including wall thickness, internal channels, overhangs, orientation, supports, and powder removal.
• Analyze print data and test results to improve density, surface quality, dimensional accuracy, repeatability, and build success rate.
• Plan and support process validation through density testing, metallography, microscopy, dimensional inspection, surface measurement, and pressure/leak testing.
• Develop and maintain process specifications, parameter records, work instructions, validation reports, and manufacturing standards.
• Transfer validated processes from development into production and provide technical support during initial manufacturing builds.
• Support continuous improvement of machine utilization, material usage, cycle time, yield, and overall process reliability.
• Provide technical guidance and training to technicians and junior engineers.
• Support safe powder handling, equipment operation, and additive manufacturing safety requirements.

Skills

LPBF/SLM parameter development

Root-cause analysis

Troubleshooting

Data analysis

Cross-functional communication

DFAM/DOE/CPk

Education

Bachelor's degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, Metallurgical Engineering, or a related field

Tools

Materialise Magics

3DXpert

Netfabb

EOSPRINT

Siemens NX

Job description

Aegis - an Airsys Company is seeking an experienced Additive Manufacturing Process Engineer to develop, optimize, validate, and support metal LPBF/SLM processes. You will focus on parameter development, complex build troubleshooting, and transferring validated processes into production.

You will lead process windows, build strategies, and defect root-cause analysis while collaborating with design, manufacturing, and quality teams to ensure robust process documentation and training.