Additive Manufacturing Engineer

HavocAI • East Providence, RI

58d • Hybrid

About The Position

We are seeking an Additive Manufacturing Engineer to join our Hardware Engineering team. This role focuses on the operation, programming, and optimization of large-format additive manufacturing (LFAM) systems. The ideal candidate will be responsible for overseeing additive manufacturing workflows for 3-axis and 5-axis printing systems, and redesigning vehicle components and systems for additive production. The engineer will play a key role in advancing our use of additive technologies to enable lightweight, high-performance designs across platforms.

Requirements

• 7+ years of experience in additive manufacturing or advanced manufacturing engineering.
• Proficiency with CAD modeling and design tools such as SolidWorks, NX, or Fusion 360.
• Hands-on experience operating, maintaining, and programming industrial 3D printers (preferably large-format systems).
• Strong understanding of materials used in additive manufacturing, including thermoplastics, composites, and metal powders.
• Experience redesigning components and assemblies for additive production (DfAM principles).
• Familiarity with post-processing techniques such as machining, surface finishing, plastic welding and bonding.
• Proven ability to work cross-functionally to integrate additive components into complex systems.
• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Materials Science, or a related field.
• U.S. citizenship and eligibility for a Secret Security Clearance.

Nice To Haves

• Experience with multi-axis (3 or 5-axis) additive or hybrid manufacturing systems.
• Background in marine, automotive, aerospace, or defense system design and integration.
• Familiarity with topology optimization, generative design, or finite element analysis (FEA).
• Understanding of DfAM workflows, toolpath optimization, and material behavior in large-scale printing.
• Knowledge of design for manufacturability (DFM) and process validation.
• Familiar with other manufacturing processes, particularly composites, metallic processing (CNC, sheet metal, welding, etc), injection molding and roto-molding.
• Strong problem-solving and root-cause analysis abilities.

Responsibilities

• Additive System Operation: Oversee the daily operation of large-format 3D printers, including setup, calibration, monitoring, and maintenance of 3-axis and 5-axis additive systems.
• Programming & Maintenance: Develop and refine printer programs, perform preventative maintenance, and troubleshoot hardware and process issues to ensure reliable system performance.
• Design for Additive Manufacturing (DfAM): Redesign mechanical and structural components for additive manufacturing processes, optimizing for weight, strength, printability, and performance.
• New System Design: Design and prototype new components, subsystems, and complete assemblies specifically intended for additive production.
• Material Development: Evaluate and qualify materials (polymers, composites, and metals) for use in additive manufacturing; characterize their mechanical and thermal properties.
• Process Optimization: Develop print parameters, post-processing workflows, and quality assurance methods to ensure consistent, high-quality output.
• Collaboration: Work closely with mechanical, electrical, and manufacturing engineers to integrate additive-manufactured components into vehicle systems.
• Documentation: Maintain accurate process documentation, print records, and CAD data; develop design standards and best practices for additive workflows.
• Manufacturing Support: Collaborate with technicians and manufacturing staff to scale additive parts for production and ensure design intent translates effectively to hardware.

Benefits

• 100% Employer paid Health, Dental and Vision Insurance for you and your families
• Life Insurance
• Ability to participate in the companies 401k program
• Unlimited PTO policy with an enforced 2 week minimum
• Equity Package
• Work / Home Office Stipend
• Global Entry
• 16 Week Paid Parental Leave
• Monthly Health and Wellness Stipend

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level