Sr. Manufacturing Engineer, Inconel

VulcanForms Inc.; Ayer (MA); On-site; USD 99,584 - 136,929; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

Life insurance

401(k) plan with match

Paid time off

Job summary

VulcanForms Inc. in Massachusetts seeks a Senior Manufacturing Engineer to develop, optimize, and sustain Inconel LPBF processes for high-volume production.

This hands-on role focuses on printer performance, process capability, and production readiness while driving first-pass yield and standardized methods. You will lead cross-functional teams across Production, Quality, Materials, Equipment, and Operations to implement robust printing processes, improve machine utilization, and ensure scalable

Qualifications

• 5+ years of manufacturing engineering experience in metal additive manufacturing or high-volume environments.
• Experience with LPBF, metal AM, CNC machining, or similar processes.
• Strong knowledge of process development, SPC, RCA, and continuous improvement.
• Experience creating manufacturing docs like work instructions and specs.
• Ability to troubleshoot complex production issues and lead cross-functional teams.

Responsibilities

• Develop, qualify, and optimize Inconel LPBF processes to boost safety, quality, throughput and cost.
• Own process development from initial print params to production release.
• Troubleshoot daily print failures and process variation on the manufacturing floor.
• Analyze manufacturing data to identify trends and improve process capability with DOE.
• Create and maintain SOPs, work instructions, process specs, and manufacturing docs.
• Support machine installation, IQ/OQ activities, preventive maintenance, and readiness.
• Lead root cause investigations and implement corrective actions.
• Collaborate with Production, Quality, Supply Chain, and Mfg Eng for NPI and scale-up.
• Support PFMEA, control plans, process validation, and engineering changes.
• Mentor technicians on LPBF best practices and equipment operation.
• Ensure safety, quality, and regulatory compliance while promoting excellence.

Skills

Manufacturing engineering

Statistical process control

Cross-functional collaboration

Tools

MES/ERP systems

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.

Job Purpose

As a Senior Manufacturing Engineer, you will play a critical role in developing, optimizing, and sustaining Inconel laser powder bed fusion (LPBF) manufacturing processes within VulcanForms' advanced additive manufacturing operations. This hands‑on role will focus on driving printer performance, process capability, and production readiness for high‑volume manufacturing of nickel‑based superalloy components. Working closely with Production, Quality, Materials Engineering, Equipment Engineering, and Operations teams, you will develop robust printing processes, optimize machine utilization, improve first‑pass yield, and implement standardized manufacturing methods that enable safe, repeatable, and scalable production. You will provide day‑to‑day technical leadership on the manufacturing floor while driving continuous improvement across printing operations, process stability, equipment reliability, and product quality.

Key Responsibilities

• Develop, qualify, and optimize Inconel LPBF manufacturing processes to improve safety, quality, throughput, and cost.
• Own process development for new products from initial print parameter development through production release.
• Support daily production by troubleshooting print failures and process variation.
• Analyze manufacturing data to identify trends, improve process capability, and reduce variability using statistical methods and DOE techniques.
• Develop, validate, and maintain standard operating procedures, work instructions, process documentation, and manufacturing specifications.
• Support machine installation, IQ/OQ activities, preventative maintenance strategies, and production readiness.
• Lead root cause investigations for quality escapes, build failures, scrap, and process deviations while implementing sustainable corrective actions.
• Work cross‑functionally with Production, Quality, Supply Chain, and Manufacturing Engineering to support new product introduction (NPI) and production scale‑up.
• Support PFMEA development, control plans, process validation activities, and engineering change implementation.
• Mentor technicians and manufacturing personnel on best practices for LPBF process execution and equipment operation.
• Maintain compliance with safety, quality, and regulatory requirements while promoting operational excellence.

Qualifications

• 5+ years of manufacturing engineering experience within metal additive manufacturing, precision manufacturing, aerospace, or other high-volume manufacturing environments.
• Experience supporting laser powder bed fusion (LPBF), metal additive manufacturing, CNC machining, or similarly complex manufacturing processes.
• Strong understanding of process development, statistical process control, root cause analysis, and continuous improvement methodologies.
• Experience creating manufacturing documentation including work instructions, process specifications, and engineering standards.
• Demonstrated ability to troubleshoot complex manufacturing issues in a production environment.
• Excellent communication and cross-functional collaboration skills.
• Must be a U.S. Person due to export-controlled technologies.

Preferred Qualifications

• Experience developing manufacturing processes for Inconel or other nickel-based superalloys.
• Knowledge of metallurgy, heat treatment, residual stress management, and defect mechanisms associated with LPBF manufacturing.
• Experience with process validation, DOE, PFMEA, SPC, and Six Sigma methodologies.
• Familiarity with MES, ERP, and manufacturing data collection systems.
• Experience supporting high-volume production environments and new product introductions.
• Lean Manufacturing and continuous improvement experience.

VulcanForms offers a competitive salary and equity package. Actual compensation is based on factors such as the candidate's skills, qualifications, and experience. In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match.

The annual base salary range for this position is $99,584.00 to $136,929.00.