The Additive Manufacturing (AM) Engineer, Applications, role will assist in identifying and focusing new applications of AM technology, and work closely with customers to solve manufacturing challenges. It is required that the incumbent intimately understand the challenges present in AM aerospace applications.
Primarily, the successful candidate will work closely on metallic additively manufactured spaceflight and other supporting hardware alongside principle designers and responsible engineers. In this role, they will help optimize design for additive manufacturing (DFAM) strategies, aid/guide material and technology/machine selection, and review and uphold engineering requirements for AM applications.
Provide DFAM direction and feedback through design reviews. Assess AM part candidates for manufacturability, optimize designs and perform geometry modifications.
Review and approve AM part engineering drawings. Ensure all specifications and company standards are met during research and development activities.
Own the research, and development workflow of specific AM parts and aid in transition to production-readiness.
Aid in creation of AM Standard Operating Procedures (SOP) and electronic work instructions.
Support fabrication schedule and process planning for research , development and production components.
Help inform new technology acquisitions and AM research activities, participate in the specification for new AM systems.
Work directly with AM Programmers and AM Technicians and oversee part pre-processing, manufacturing, and post-processing. Operate AM related equipment as needed.
Cooperate with AM Production team to select scanning parameters and to successfully execute printing operations.
Develop, qualify and test AM materials and processes. Support parameter development and material characterization activities.
Characterize and specify metal powder for AM, perform incoming quality assurance tests, and manage powder inventory.
Perform metallographic and mechanical testing of AM material samples.
Perform dimensional inspection and analysis of printed parts, work with NDE engineers on inspection of AM components.
Develop and implement AM in-process inspection technologies.
Perform simulation of metal additive manufacturing techniques and evaluate impact on residual stresses, deformation, microstructure and properties.
Minimum of a B.S. degree in Industrial, Mechanical, Aerospace or Electrical Engineering or related discipline.
2+ years’ experience working with AM applications.
Experience in process definition, development, deployment, and qualification.
Strong quality mindset with special attention to safety/mission, critical quality aspects and application of root cause analysis tools.
An attitude of world-class quality, attention to detail, and dedication.
Demonstrable understanding of general AM metallic characteristics and process limitations.
Demonstrable DFAM knowledge and experience.
Proficient with Computer Aided Design (CAD).
Thorough understanding of aerospace materials and processes including heat treatment.
Experience interpreting NDE results.
Experience with metallographic preparation and mechanical testing.
Ability to communicate effectively, clearly, and with humility to stakeholders.
Must be a U.S. citizen or national, U.S. permanent resident (current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.
5+ years’ experience in aerospace or related field.
Experience with design, analysis, and production of components.
Experience transitioning products from development to production.
2+ years’ experience with AM software packages (simulation, STL preparation, exposure patterns and parameters, etc.).
2+ years’ experience operating various AM machines and related post-processing equipment.
Experience with operations and maintenance of optical systems.
Experience with 3D measurement tools, such as CMM’s, Laser Scanners.
Knowledge in the use of 3D CAD tools (PTC CREO is preferred).
Ability to read and interpret GD&T per ASME Y14.5M-1994 standard.
Knowledge of drawing and work order review and familiarity with inventory and issue tracking systems.
Working knowledge of a variety of fluids including GN2, GHe, hydraulics, rocket propellants and cryogenics.
Experience with electro-mechanical, hydraulic, and electrical subsystems.
Experience with Lean Manufacturing or Toyota Production, System. Six Sigma Black Belt certification preferred.
Knowledge of fabrication processes, integration processes, systems engineering practices, test, quality, and configuration management systems.
Excellent and demonstrable communicative skills.
Ability to operate manual machine tools (basic lathe, mill).
Ability to specify, procure and install capital equipment.
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