Advanced Process Engineer (Metal AM)

Boom Supersonic•Centennial, CO

1d•$125,000 - $205,000•Onsite

About The Position

Boom is developing advanced gas turbine engines for energy generation and supersonic flight, utilizing high-temperature nickel superalloys. Additive manufacturing (AM) is crucial for producing these parts on schedule. This role is central to establishing and operating a new metal AM line, including machines, parameters, applications, and quality systems. Unlike established AM roles, this position involves developing processes from scratch for challenging alloys on cutting-edge equipment, requiring significant innovation and ownership of application development for real engine components.

Requirements

Bachelor's, Master's, or PhD in engineering with a focus on materials, manufacturing, or additive manufacturing.
5+ years of experience in LPBF process and/or applications development on real programs with customers and consequences (exceptional depth can substitute for years).
Hands-on LPBF experience, including loading powder, setting up builds, monitoring them, and debugging failure modes.
Demonstrated process development ownership, including developing parameters, designing DOEs, and diagnosing/resolving failure modes.
Working knowledge of build-preparation software (e.g., Dyndrite, Magics, 3DXpert, EOSPrint, Netfabb).
Programming experience, preferably Python, with an aptitude for automation.
Strong documentation and traceability habits suitable for quality audits.
Must be a U.S. citizen, lawful permanent resident, protected individual, or eligible for required U.S. Department of State authorizations due to ITAR/EAR regulations.

Nice To Haves

Experience with high-temperature, crack-prone nickel superalloys, specifically high gamma prime alloys.
Experience on high-preheat LPBF platforms or with reactive metal alloys.
Materials evaluation experience, including metallography, SEM, tensile/fatigue/creep testing, fractography, and powder characterization.
Exposure to qualification programs (allowables thinking, MMPDS/CMH-17 concepts, statistical treatment of material data).
Experience transitioning a process from R&D to production in a regulated environment (AS9100 or similar).
Startup or prototype-pace experience, with comfort in a lab where processes are still being developed and priorities can shift rapidly.

Responsibilities

Design and execute Design of Experiments (DOEs) for difficult-to-print metal alloys on production LPBF machines and document findings.
Develop process parameters from scratch for extreme-preheat platforms printing crack-prone superalloys.
Own part-specific application development, including build orientation, support strategy, distortion compensation, depowdering, heat treat and HIP specification, machining interfaces, and inspection plans.
Automate processes such as programmatic DOE generation and build preparation to reduce manual work and speed up file setup.
Write documentation for the transition of processes from R&D to production, including procedures, work instructions, build records, powder reuse tracking, and traceability.
Assist in scoping, procuring, installing, and commissioning equipment, and subsequently use and train others on it.
Collaborate closely with technicians and M&P engineers in the lab environment, participating in building, documenting, and troubleshooting.