Additive Manufacturing Engineer
About The Position
Leidos' Defense Systems is seeking an Additive Manufacturing Engineer to join the Advanced Materials Department. This department provides materials engineering expertise across all program phases, with backgrounds in materials science, chemistry/chemical engineering, and physics. They support R&D, prototype development, and manufacturing design and build tasks, equipped with analysis equipment, multi-physics modeling capabilities, and experimental lab space. The Defense Systems Sector offers a diverse portfolio of systems, solutions, and services for customers worldwide, focusing on solving tough security challenges for missions that cannot fail.
Requirements
- Resident of North Alabama or willing to relocate to work on-site in Huntsville, AL.
- Hands-on experience with metal additive manufacturing engineering
- Experience with and basic understanding of design for additive manufacturing (DfAM), especially with Powder Bed Fusion, DED, and/or Cold Spray.
- Experience with metal additive manufacturing support structure design.
- Experience setting up metal builds with software like Materialise Magics, Oqton 3DXpert, EOSPrint, etc.
- Ability to support hardware systems including setup, operation, and troubleshooting of AM equipment.
- Familiar with high strength/temperature metal alloys (nickels, HEAs, refractories, etc.)
- Bachelor’s degree with a minimum 3.2 GPA in mechanical engineering, materials science, manufacturing engineering, or a related field from an ABET accredited university. 4 additional years of experience required in lieu of bachelors degree.
- 4+ years experience in metal additive manufacturing, or MS with 2+ years experience, or PhD with 1+ years experience (8 total minimum years of experience without a college degree)
Nice To Haves
- Hands-on experience with the following metal additive manufacturing processes: Laser Powder Bed Fusion (LPBF), Cold Spray Additive Manufacturing, Directed Energy Deposition (DED), and Wire Arc Additive Manufacturing (WAAM)
- Experience with build parameter development, process development/optimization, and qualification.
- Familiarity with post-processing methods including heat treatment, machining, and surface finishing.
- Experience with simulation tools for additive manufacturing (thermal, distortion, support optimization).
- Exposure to in-situ monitoring systems or sensor integration in AM platforms.
- Programming or scripting experience (Python, MATLAB, or similar) for data analysis or workflow automation.
- Hands on experience preparing mechanical testing, including monotonic, fatigue, creep, etc.
- Experience with metallurgical specimen preparation and inspection
- Experience in communicating with external vendors or in contract manufacturing
- Experience obtaining quotes for work and equipment
- Experience writing proposals
- Design experience on Solidsworks, Creo, or other CAD systems
- Experience troubleshooting and maintaining complex AM equipment, including laser optics, process monitoring
- Experience working with hazardous materials
- Experience writing standard operating procedures and safety work practices documents
- Experience setting up AM equipment and training others on equipment
Responsibilities
- Design for additive manufacturing (DfAM)
- Developing plans and layouts for additive manufacturing equipment and capabilities
- Contributing to multiple program teams as the resident additive manufacturing expert across multiple metal additive technologies
- Performing additive manufacturing analyses including cost, feasibility, deformation, expected material/component mechanical and thermal properties
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What This Job Offers
Job Type
Full-time
Career Level
Senior
