Additive Manufacturing Process Qualification & Supplier Development Lead Engineer

Honda Aero, LLC. • Burlington, NC

3d

About The Position

The AM Process Qualification and Production Industrialization Technical Lead serves as Honda’s technical authority for metal laser powder bed fusion (LPBF) equipment and processes, translating that expertise into practical qualification requirements for aerospace components. The role evaluates, develops, and technically guides in-house and external manufacturing sources toward stable, repeatable, production-capable AM processes.

After qualification, the position establishes production processes by translating qualified conditions into robust manufacturing methods, equipment and process controls, requirements, and standard operating procedures. It provides technical leadership during production ramp-up and process stabilization, significant changes, and AM-related issues. In collaboration with Quality Assurance and Parts Quality, the role retains ownership of AM equipment, process capability, and manufacturing-technology decisions.

The work spans office, laboratory, and manufacturing-floor activities in controlled AM environments. Required PPE and metal-powder safety practices must be followed. Domestic and international travel and meetings with global teams are expected based on project needs. Ability to lift more than 25 lbs. is required, and limited overtime may be needed.

Requirements

• Bachelor’s degree in mechanical engineering, Materials Engineering, Aerospace Engineering, Manufacturing Engineering, or equivalent experience.
• At least 5 years of relevant experience in metal LPBF process development, AM machine and process qualification, manufacturing-source development, and production-process establishment.
• Strong hands-on experience with production metal LPBF equipment, including setup, calibration or verification, parameter development, powder handling, build execution, troubleshooting, and maintenance-related process impacts.
• Demonstrated ability to analyze AM process data and failures and identify effective technical countermeasures.
• Ability to interpret engineering drawings, including GD&T, tolerances, and manufacturability considerations.
• Strong practical engineering skills and ability to independently perform hands-on technical work.
• Ability to organize and execute technical projects, track schedules, and contribute to issue resolution across cross-functional teams.
• Ability to write clear, structured engineering documents and communicate technical content effectively.
• Ability to manage multiple tasks, maintain detailed records, and ensure appropriate process traceability.
• Effective communication and collaboration across international and cross-functional teams.
• Ability to lift more than 25 lbs.
• Ability to maintain a safe, clean, and controlled AM work environment and follow required PPE and metal-powder safety practices.

Nice To Haves

• Working knowledge of AMS 7003, AMS 7032, aerospace material/process qualification, or comparable controlled-manufacturing requirements.
• Experience with production LPBF systems, including multi-laser platforms such as EOS M400-4 or comparable equipment.
• Knowledge of aerospace quality frameworks such as AS9100 or AM certification concepts, including FAA guidance AC35.15-3 or EASA CM-S-008.

Responsibilities

• Maintain practical expertise in LPBF equipment and processes, including operation, calibration, maintenance, parameters, powder behavior, build preparation, monitoring, and post-processing.
• Lead or direct process development, design of experiments, engineering trials, data analysis, and root-cause investigations for AM equipment and process issues.
• Independently assess manufacturing-source proposals, trial results, process limitations, and technical risks.
• Translate LPBF knowledge into qualification requirements, test methods, and acceptance criteria.
• Define the technical content of machine and process qualification, including parameter control, equipment condition, powder and build controls, repeatability, and production demonstration.
• Review qualification plans and results, identify technical gaps, and recommend readiness for development, qualification, or production stages.
• Partner with Quality Assurance, Parts Quality, Materials, Design, and Certification while leading decisions concerning AM equipment performance, process capability, and technical qualification adequacy.
• Evaluate and develop the AM technical capability of internal and external manufacturing sources, including equipment, process controls, troubleshooting, staffing, and ability to sustain repeatable production.
• Translate qualified conditions into production processes covering build preparation, equipment verification, parameter and powder controls, monitoring, post-processing interfaces, technical work requirements, and reaction plans.
• Provide technical direction during production planning, pilot builds, ramp-up, and stabilization to close capability gaps and achieve repeatable quality, yield, throughput, and cost performance.
• Assess whether equipment, process, material, software, or production changes could affect a qualified AM process and require verification or requalification.
• Apply lessons learned and proven methods to future parts, machines, materials, and manufacturing sources.
• Maintain a safe, clean, and controlled AM work environment and follow required PPE and metal-powder safety practices.
• Organize and execute technical projects, track schedules, support cross-functional issue resolution, maintain detailed records, and ensure process traceability.

Benefits

• Competitive base wages, based in part on geographic location and work experience.
• Paid overtime.
• Regional bonus when applicable.
• Medical, dental, vision, and prescription benefit plans.
• Paid time off, including vacation, holidays, and shutdown.
• Company-paid short-term and long-term disability.
• 401(k) plan with company match and additional contribution.
• Advancement opportunities and career mobility.
• Education reimbursement for continued learning.
• Training and development programs.
• Lifestyle account.
• Childcare reimbursement account.
• Tuition assistance and student loan repayment.
• Elder care support.
• Wellbeing program.
• Community service and engagement programs.
• Product programs.

What This Job Offers

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