Additive Manufacturing Engineer

Leidos•Huntsville, AL

2d•Onsite

About The Position

Leidos Dynetics’ Advanced Materials Department is seeking a passionate, detail-oriented problem-solver to serve as an Additive Manufacturing Materials Engineer. With offices across the United States engaging in the defense, space, cyber and commercial fields, Leidos provides responsive, cost-effective engineering, scientific and IT solutions. The Advanced Materials Department is a multi-disciplinary team that provides materials engineering expertise for every phase of a program. With backgrounds in materials science, chemistry/chemical engineering, physics, among others, the department has experience in executing a variety of efforts from R&D, to prototype development, to supporting design and build tasks for manufacturing. Beyond subject matter expertise, the department has the analysis equipment, multi-physics modelling capability and experimental lab space to support activities ranging from proof-of-concept experimentation to manufacturing support. As an integral member of the Advanced Materials Department, the successful candidate will balance multiple activities including but not limited to: - Metallurgical and material science analysis and recommendations for multiple programs, guiding the successful use of additive manufacturing. - Starting with a desired application, provide recommendations on AM technology and materials; perform trades on capability, cost, lead time, post processing, defects, deformation, expected material/component mechanical and thermal properties at both the microstructural and macro level. - 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 - Design for additive manufacturing (DfAM)

Requirements

Resident of North Alabama or willing to relocate to work on-site in Huntsville, AL.
Experience in metallurgy/material science of additively manufactured materials
Understanding of/ability to quantify expected material property outcomes based on microstructure and metallurgical mechanisms common in additively manufactured aerospace alloys
Familiar with high strength/temperature metal alloys (nickels, HEAs, refractories, etc.)
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 metallurgical specimen preparation and inspection
Bachelor’s degree with a minimum 3.2 GPA in materials engineering, materials science, manufacturing engineering, or a related field from an ABET accredited university.
5+ years experience in metal additive manufacturing, or MS with 2+ years experience, or PhD with 1+ years experience

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)
Hands on experience preparing mechanical testing, including monotonic, fatigue, creep, etc.
Experience setting up metal builds with software like Materialise Magics, Oqton 3DXpert, EOSPrint, etc.
Experience with metal additive manufacturing support structure design.
Ability to support hardware systems including setup, operation, and troubleshooting of AM equipment.
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.
Experience in communicating with external vendors or in contract manufacturing
Experience obtaining quotes for work and equipment
Experience writing proposals
Design experience on SolidWorks, 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

Metallurgical and material science analysis and recommendations for multiple programs, guiding the successful use of additive manufacturing.
Starting with a desired application, provide recommendations on AM technology and materials; perform trades on capability, cost, lead time, post processing, defects, deformation, expected material/component mechanical and thermal properties at both the microstructural and macro level.
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
Design for additive manufacturing (DfAM)