Senior Product Development Engineer, Consumer Electronics

VulcanForms Inc.; Ayer (MA); On-site; USD 106,000 - 171,000; Full time

Job summary

VulcanForms Inc. in the United States seeks a Sr.

NPI Product Development Engineer to architect and optimize high-speed LPBF processes and digital workflows, bridging R&D breakthroughs to serial production and delivering production-ready parts for strategic global customers. You will lead cross-functional teams across hardware, software, materials, and operations, define platform standards, mentor engineers, and drive CAPA and DfAM initiatives to maximize print quality and manufacturing

Qualifications

• 3+ years of hands-on experience in product or applications development with a track record of scaling LPBF/DED processes into high-volume manufacturing.
• Expert-level proficiency in advanced 3D CAD software and build-preparation tools (e.g., Siemens NX, Creo, SolidWorks, Magics, nTopology, Amphyon).
• Deep mastery of GD&T, statistical process capability, tolerance stack‑up analysis, and DFM/DfAM constraints.
• Outstanding leadership and communication skills with the ability to influence roadmaps and mentor engineering talent.
• Strong working knowledge of subtractive manufacturing (5-axis milling, turning, EDM) and integration with additive workflows.

Responsibilities

• Architect, govern, and scale LPBF process workflows from R&D to high-volume serial production.
• Lead development and standardization of LPBF process recipes and build configurations.
• Translate customer and market requirements into engineering specifications and drive DfAM.
• Oversee First Article Inspections and production launches for aerospace, defense, medical, and semiconductor.
• Act as SME for tier-one customers, program management, and executives.
• Own root-cause investigations for print defects and drive CAPA with data analytics.
• Collaborate with downstream teams to embed DFM principles from day one.
• Mentor junior engineers and establish SOPs and quality control standards.

Skills

LPBF scaling

Leadership

Communication

Mentoring

Education

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

Master’s or Ph.D. preferred

Tools

Siemens NX

Creo

SolidWorks

Magics

nTopology

Amphyon

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 Sr. NPI Product Development Engineer at VulcanForms, you will serve as a principal technical leader responsible for architecting and optimizing our high‑speed laser powder bed fusion (LPBF) processes and advanced digital workflows. Your mission is to bridge the gap between complex R&D breakthroughs and full serial production, establishing scalable engineering frameworks that ensure unmatched print quality, system reliability, and manufacturing efficiency across the entire organization. You will act as a primary technical authority, influencing cross‑functional roadmaps across hardware, software, materials, and operations to deliver high‑consequence, production‑ready parts for our most strategic global customers.

Key Responsibilities

• Architect, govern, and scale integrated LPBF process workflows from initial R&D through high‑volume serial production, systematically elevating Manufacturing Readiness Levels (MRL) across the organization.
• Lead the development, standardization, and optimization of core LPBF process recipes and complex build configurations; define the platform standards that ensure repeatability and traceability across the VulcanForms fleet.
• Synthesize highly complex customer and market requirements into foundational engineering specifications; champion top‑down Design for Additive Manufacturing (DfAM) methodologies that maximize geometric freedom while balancing supports, tolerances, and metallurgical performance.
• Oversee the technical execution of First Article Inspections (FAI) and critical production launches for high‑stakes industries, including aerospace, defense, medical, and semiconductor.
• Serve as the definitive technical subject matter expert (SME) for tier‑one customers, program management, and executive leaders—driving alignment on production roadmaps, steering technical reviews, and resolving high‑priority engineering challenges.
• Own systemic root cause investigations for complex print defects, implementing org‑wide corrective and preventive actions (CAPA) through advanced data analytics and iterative testing.
• Drive cross‑functional collaboration with downstream automation, machining, and finishing process owners to embed comprehensive Design for Manufacturing (DFM) principles from day one.
• Mentor and coach junior and mid‑level engineers, fostering a culture of technical excellence; establish standard operating procedures (SOPs), quality control standards, and change‑management logs to ensure strict production compliance.

Qualifications

• 3+ years of progressive, hands‑on experience in product or applications development, with a documented track record of scaling LPBF or directed energy deposition (DED) processes into high‑volume manufacturing environments.
• Bachelor’s degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a related field; Master’s or Ph.D. is highly preferred.
• Expert‑level proficiency in advanced 3D CAD software (e.g., Siemens NX, Creo, SolidWorks) along with specialized build‑preparation tools (e.g., Magics, nTopology, Amphyon).
• Deep mastery of GD&T, advanced statistical process capability, tolerance stack‑up analysis, and complex DFM/DfAM constraints.
• Outstanding leadership and communication skills, with a proven ability to influence technical roadmaps, align multidisciplinary stakeholders, and mentor engineering talent.
• Strong working knowledge of subtractive manufacturing operations (5‑axis milling, turning, EDM) and their integration with additive workflows.

Benefits

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 $106,000 to $171,000.