Additive Manufacturing (AM) Technology Engineer (Senior Principal Engineer)

Caterpillar•San Diego, CA

8d•Onsite

About The Position

Caterpillar is hiring an Additive Manufacturing (AM) Technology Engineer to advance AM technology, materials, and component applications. The role uses the Technology Readiness Level (TRL) framework to mature technologies such as qualification of new AM components, distortion prediction, low-angle printing strategies, surface finishing, print parameter optimization, and process monitoring and quality assurance. The engineer identifies high-impact applications and develops pathways to address technical gaps and risks. The role captures and shares Design for Additive Manufacturing (DFAM) knowledge through technical documentation, training, consulting, and support for component design, manufacturing, and field teams. It also supports characterization and mechanical-property testing of commercial and emerging AM alloys, including nickel and stainless steels, and collaborates with internal and external partners to qualify alloys and develop material-property design curves. The engineer partners with NPI leadership, Product Owners, and development teams to identify applications, evaluates design tradeoffs, develops risk-mitigation and qualification plans, and collaborates across functions to execute technology-development projects. The role applies mechanical design principles and analytical tools, provides technical guidance and mentorship, and serves as a DFAM technical authority. This position is onsite five days a week. Visa sponsorship is not available.

Requirements

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or another engineering discipline.
Demonstrated experience applying DFAM principles to the design, development, and qualification of new AM components.
Strong proficiency with 3D modeling and engineering analysis tools and methods, including Ansys, Space Claim, and Creo.
Experience with engineering drawings, BOM development using Windchill and Linked Data, and configuration management.
Ability to interpret and apply analysis results to support design decisions.
Extensive experience designing, developing, and qualifying turbomachinery components.
Strong understanding of manufacturing processes, product development, and design-for-manufacturability principles.
Demonstrated ability to work cross-functionally across disciplines to solve complex engineering and organizational challenges.
Ability to independently solve complex technical problems and provide technical leadership across functional boundaries.
Experience mentoring engineers and contributing to organizational technical capabilities.
Excellent written and verbal communication skills with technical and non-technical stakeholders.

Nice To Haves

Extensive experience delivering technical presentations or speaking at industry conferences.
Strong record of documenting project results, including EDMs and research reports, and creating standard-work documentation such as design-manual contributions, work instructions, guidance notes, process maps, and KMS entries.
Strong written and verbal Spanish communication skills.

Responsibilities

Partner with NPI leadership, Product Owners, and development teams to identify high-impact AM applications that accelerate NPI, enhance product capabilities, and provide supply-chain flexibility.
Lead technical evaluation of tradeoffs and design alternatives for AM components, including safety, performance, reliability, manufacturability, cost, serviceability, and risk.
Identify technical risks and develop mitigation strategies for AM technology-development programs.
Develop technology-maturation and qualification plans for new AM components or technologies for development and production applications.
Communicate and collaborate with cross-functional teams to execute AM technology-development projects.
Apply advanced mechanical-design principles and analytical tools to support design decisions and resolve complex engineering challenges for new AM components.
Provide AM-related technical guidance and mentorship to engineers, supply chain, and manufacturing teams across experience levels.
Serve as a DFAM technical authority and resource, establish engineering best practices, and share lessons through training and mentoring.
Advance AM technologies using the TRL framework, including component qualification, distortion prediction, low-angle printing strategies, surface finishing, print-parameter optimization, and process monitoring and quality assurance.
Identify high-impact AM component applications and develop pathways to address technical gaps and risks.
Document AM best practices in Solar KMS, design manuals, and EDM reports; lead periodic in-house training and advise component design teams as an AM subject matter expert.
Support manufacturing, design, and field teams with root-cause and corrective-action activities.
Monitor AM advances in industry and universities and identify promising emerging technology opportunities.
Support metallurgical characterization and mechanical-properties testing of commercial and emerging AM alloys, including nickel and stainless steels.
Collaborate with universities, laboratories, M&P, and SMEs to qualify new AM alloys; work with cross-functional engineering teams to develop material-property design curves and qualify new AM components.