Senior Submarine Additive Manufacturing Engineer

Serco; Fredericksburg (VA); On-site; USD 120,000 - 180,000; Full time

Job summary

Serco seeks a Senior Additive Manufacturing Engineer to support the Virginia Class Submarine Program (PMS450) in the Washington, DC area. You will design, develop, and test additive processes, lead technical reviews, and optimize production with a focus on powder-bed and powder-fed methods.

The role requires a DoW Secret clearance, a mechanical engineering degree, and 10+ years in propulsion or metallic AM. Strong communication and teamwork are essential for success.

Qualifications

• Active DoW Secret security clearance required.
• Bachelor’s degree in mechanical engineering or related field.
• Minimum 10 years in propulsion component design or metallic additive tech.
• Strong verbal and written communication; ability to brief senior leaders.
• Experience with Navy submarines or DoD programs is a plus.

Responsibilities

• Design, develop, and test additive manufacturing processes for military applications.
• Lead and coordinate acquisition management solutions and risk mitigation.
• Review production data, evaluate AM changes, and optimize print parameters.
• Collaborate with Materials Engineers on print parameters and alloys.
• Prepare reports, procedures, and manuals to mature development processes.

Skills

Additive manufacturing

Aerospace/Navy experience

Engineering analysis

Communication skills

Team leadership

Education

Bachelor’s degree in mechanical engineering

Master’s degree in aeronautical/astronautical/mechanical engineering

Tools

FEMAP

ANSYS

CAD software

Job description

Position Description & Qualifications

If you seek a rewarding, high profile and challenging position supporting projects for the US Navy- Serco has a terrific opportunity for you!

As the Senior Additive Manufacturing (AM) Engineer, you will be on a dynamic team providing technical and programmatic support to the VIRGINIA Class Submarine Program (PMS450) and the U.S. Navy’s Team Submarine Program Offices! Bring your expertise and collaborative skills to make an impact on our military defense and safety of our sailors and contribute and influence the Navy's future, premier nuclear submarines.

Must possess an active U.S. Department of War (DoW) Secret security clearance

Team Submarine unites the Program Executive Officer, Undersea Warfare Systems (PEO UWS); the Deputy Commander, Undersea Technology (SEA 07); Program Executive Officer, Attack Submarine (PEO SSN); Program Executive Officer, Strategic Subs (PEO SSBN) and the Submarine Maintenance Engineering, Planning, and Procurement (SUBMEPP) Activity, once diverse submarine-related commands and activities, into a single "submarine-centric" team. Conceived to increase efficiencies within the submarine acquisition, maintenance, and modernization communities, Team Submarine eliminates traditional "stovepipe" structures and processes that created impediments and inefficiencies in the submarine research, development, acquisition, and maintenance communities. Team Submarine provides improved communication among the various offices that contribute to the overall success of the United States Submarine Force.

The Virginia Class Submarine Program (PMS450) is responsible for the design, construction, certification, and delivery of Virginia Class Submarines. Virginia Class Submarines (VCS) are built to seek out and destroy enemy ships/submarines, working both independently and in concert with carrier strike groups/other ships, providing Joint Commanders with early, accurate knowledge of the battlefield; covert striking power against targets ashore; and the maritime strength to destroy enemy naval forces and interdict seaborne commerce. U.S. Navy submarines ARE the undersea advantage against our adversaries.

We are looking for an energetic, enthusiastic and exceptional person to serve as the Senior AM Engineer for PMS 450 in the Washington, DC area. The Senior AM Engineer is responsible for design, development, and testing of all facets of the additive process with a focus on machines, software, part design and analysis, and additive techniques.

In this role, you will:

• The Senior AM Engineer plays a key role in planning and developing Acquisition Management solutions, working on mid-level initiatives and supporting clients through technical expertise.

• Provide AM engineering consulting support and participate in technical reviews, conduct engineering analyses of systems and sub-systems in terms of operability, technical merit, and schedule risk.

• Review and evaluate production design data and documentation; prepare, test and evaluate AM engineering changes; and conduct analyses of ability to produce and production operations, processes, and systems in production items.

• Provide recommendations for the technical directorate team coordination and risk mitigation strategies associated with production and migration.

• Advise and recommend strategies for issues including migration, program schedule, and infrastructure upgrades.

• Rely on extensive experience and judgment to plan and accomplish goals.

• May lead and direct the work of others.

• A wide degree of creativity and latitude is expected.

• Typically reports to the Technical Director or APM.

• Proven ability to work independently and and in a team.

• Strong technical and analytical skills.

• Be an active contributor within a team of engineers who perform the design, development, and testing of all facets of the additive process using powder-bed and powder-fed approaches

• Generate optimized build files to produce high-quality parts in minimum time with maximum consistency

• Work with other engineers to help refine the design of existing parts and optimize new parts to leverage additive technology

• Work with Materials Engineers to investigate properties, geometric accuracy, and surface finish results to develop optimal print parameters, heat treatments, and design allowables for existing and new alloys

• Work interdisciplinary trades on processes that result in optimal additive part production

• After hardware is produced, communicate results and feedback to Responsible Engineers to continuously develop and improve hardware production

• Produce reports, procedures, and manuals to document results to mature development processes for production

To be successful in this role, you will have:

• Must possess an active DoW Secret security clearance.

• Bachelor’s degree in mechanical engineering, or other engineering disciplines.

• Minimum 10 years of experience in propulsion component design or development of metallic additive technologies.

• Excellent communications and analytical skills; able to meet with program officials and influence actions needed to meet technical program milestones.

• Experience briefing senior leaders.

• Proficient with MS Office products i.e., Excel, PowerPoint, Word, and Outlook.

• Excellent communications and analytical skills; able to meet program officials and develop and implement actions needed to meet program milestones.

• Must have the ability to work both in a team environment and independently, and often under short, multiple deadlines.

• The ability to travel up to 10%.

Preferred skills and experience:

• Master’s degree in aeronautical, astronautical, or mechanical engineering.

• Experience with operating additive machines, including parameter development and process control.

• Experience with additive simulation software.

• Experience with topology optimization software.

• Knowledge of various additive and subtractive manufacturing and joining techniques for metals.

• Solid understanding of optics and lasers.

• Familiarity with common engineering materials properties (strength, life, thermal, fluid compatibility etc.) and processing attributes particularly for titanium or nickel-based alloys.

• Experience with detailed design and operation of propulsion fluid components (e.g., valves).

• Experience with setting up and running multifactorial design of experiments (DOE’s).

• Ability to perform trade studies using first principles and engineering fundamentals.

• Proficient in basic principles of compressible and incompressible flow, thermodynamics, thermochemistry, mechanics, materials, and electrical circuits.

• Experience with Finite Element Modeling and Postprocessing (FEMAP), Analysis System (ANSYS), and similar structural analysis software tools.

• Hands‑on experience with aerospace components or fluid system testing, including pressure, hot‑fire, and environmental testing.

• Navy Fleet submarine operational experience.

• Technical knowledge of SUBSAFE program.

• 10 years of experience with Navy acquisition and Submarine Programs.

• Recent experience in Team Submarine would be ideal.

• Submarine Engineering experience is a plus.

• Experience supporting a submarine acquisition program.

• Typical technical or engineering experience and expertise in working with the DoW acquisition programs and processes.

• Experience in developing technical standards.

• Engineering and acquisition fundamentals, as well as expertise with undersea shipbuilding programs.

• Strong quantitative, analytical and conceptual thinking skills.

Company Overview

Serco Inc. (Serco) is the Americas division of Serco Group, plc. In North America, Serco’s 9,000+ employees strive to make an impact every day across 100+ sites in the areas of Defense, Citizen Services, and Transportation. We help our clients deliver vital services more efficiently while increasing the satisfaction of their end customers. Serco serves every branch of the U.S. military, numerous U.S. Federal civilian agencies, the Intelligence Community, the Canadian government, state, provincial and local governments, and commercial clients. While your place may look a little different depending on your role, we know you will find yours here. Wherever you work and whatever you do, we invite you to discover your place in our world. Serco is a place you can count on and where you can make an impact because every contribution matters.

To review Serco benefits please visit: https://careers.serco-na.com/us/en/what-we-offer . If you require an accommodation with the application process please email: [e-mail] or call the HR Service Desk at 800-628-6458, option 1. Please note, due to EEOC/OFCCP compliance, Serco is unable to accept resumes by email.

Candidates may be asked to present proof of identity during the selection process. If requested, this will require presentation of a government‑issued I.D. (with photo) with name and address that match the information entered on the application. Serco will not take possession of or retain/store the information provided as proof of identity. For more information on how Serco uses your information