Sr. Metal Additive Process Engineer

Fusion Life Science Technologies LLC; Irvine (CA); On-site; USD 120,000 - 160,000; Full time

Job summary

Fusion Life Science Technologies LLC in Irvine, CA is seeking a Senior Metal Additive Process Engineer to lead development, optimization, and scale-up of metal 3D printing processes. You will operate equipment, run experiments, and analyze data to establish robust manufacturing windows and qualify parts.

The role emphasizes hands-on parameter development, DOE studies, and problem-solving across powder handling, post-processing, and production transfer.

Qualifications

• Hands-on experience with metal additive manufacturing
• Strong understanding of powder behavior and melt pool dynamics
• Experience designing and executing DOE studies with statistical analysis
• Strong troubleshooting and root-cause investigation skills

Responsibilities

• Operate, maintain, and optimize metal additive manufacturing systems.
• Develop and refine print parameters to improve build quality, productivity, and yield.
• Design and execute DOE studies to identify and optimize critical process parameters.
• Troubleshoot printing, powder handling, and post-processing issues using engineering and statistical methods.
• Support equipment and part qualification, process validation, and scale-up into production.

Skills

Metal AM processes

Powder behavior

DOE design & statistics

Troubleshooting & root-cause

Education

BS/MS in Mechanical Engineering or Materials Science

Job description

Title: Sr. Metal Additive Process Engineer

Location: Irvine, CA

Duration: 6 Months possible extension.

Position Summary

Lead the development, optimization, and scale-up of metal additive manufacturing (metal 3D printing) processes through hands-on operation of metal printing equipment, experimental design, and data analytics. Drive process understanding, establish robust manufacturing windows, and qualify parts and components.

Key Responsibilities

• Operate, maintain, and optimize metal additive manufacturing systems.
• Develop and refine print parameters to improve build quality, productivity, and yield.
• Design and execute DOE studies to identify and optimize critical process parameters.
• Troubleshoot printing, powder handling, and post-processing issues using engineering and statistical methods.
• Support equipment and part qualification, process validation, and scale‑up into production.

Must-Have Skills

• Hands‑on experience with metal additive manufacturing technologies.
• Strong understanding of metal powder behavior, melt pool dynamics, process parameter development, and defect mechanisms.
• Experience designing and executing DOE studies and applying statistical analysis.
• Strong troubleshooting and root‑cause investigation skills.

Nice‑to‑Have Skills

• Machine learning, AI, or predictive modeling for process optimization.
• Design for Additive Manufacturing (DfAM).
• Thermal modeling, FEA, or simulation of metal AM processes.

Preferred Qualifications

• BS/MS in Mechanical Engineering, Materials Science, Manufacturing Engineering, or related discipline.
• 5+ years minimum of experience in metal additive manufacturing process development. (7-10 years' experience would be preferred).