Engineer IV

General Atomics•Poway, CA

8d•Onsite

About The Position

General Atomics Aeronautical Systems, Inc. (GA-ASI), an affiliate of General Atomics, is a world leader in proven, reliable unmanned aerial systems (UAS) and tactical reconnaissance radars, as well as advanced high-resolution surveillance systems. We have an exciting opportunity for a dynamic and proactive Directed Energy Deposition (DED) Metal Additive Manufacturing Engineer in our Additive Manufacturing (AM) department located in Poway, CA. This position will support the DED metal AM production and development efforts at GA-ASI in design (DfAM), process and parts qualification, first article, metrology/inspection, tests, technology assessment and novel DED manufacturing technology development. Although it is part of the Manufacturing Operations group, this position will be a key interface role between various other internal and external stakeholders such as Design engineering, Materials & Processes engineering, Structures, Programs management, and Supply Chains as serving as subject matter expert (SME) to help integrate DED metal AM into GA-ASI’s products and processes. This position will provide the candidate with a lead role opportunity into the growth of DED metal AM at GA-ASI.

Requirements

Extensive experience with Directed Energy Deposition (DED) technologies metal AM as a designer, and/or as a user of DED to manufacture industrial parts.
Experience with the entire metal DED AM production workflow from business benefits considerations, design, pre-print considerations and planning, printing, post-processing and qualification process.
Specific interest in DED-wire based processes using Titanium and Aluminum materials.
Experience with metal DED AM printers and associated post-processing equipment and safety procedure
Adjacent working knowledge of some other key metal AM technologies, and their associated characteristics and applicability/use cases (e.g. metal LPBF, polymer powder SLS, polymer filament FDM/FFF, etc.).
Working knowledge of most of AM-relevant metrology and heat treatment technologies applied to metal-DED parts.
Experience with Design for Additive Manufacturing (DfAM), specifically related to metal DED AM.
Ability to demonstrate/provide examples of designs achieved or involved with.
Proficiency with a major CAD platform (e.g. Siemens Nx, CREO, CATIA, ProE, etc.)
Experience with metal DED AM suppliers (materials and hardware providers, software providers, contract manufacturers, etc.)
Background knowledge of conventional manufacturing processes (complementary to metal DED AM, such as CNC machining, casting, forging, welding, etc.)
Clearly and effectively communicate both verbally and in written form to both technical and non-technical audiences, especially regarding manufacturing processes, engineering issues and proposed changes, and quality issues and dispositions.
Ability to form and foster rich AM networking and keep engaged.
Experience with Microsoft Office PowerPoint, Project, Excel and Visio.
Must be able to work both independently and in a team environment.
Must be self-driven, like to innovate, and with desire to increase his/her knowledge.
Ability to influence others, develop a plan and rally a team around it, lead small team.
Ability to obtain and maintain DoD Secret Clearance is required.

Nice To Haves

Experience with MRP systems is an advantage, (e.g. SAP).

Responsibilities

Subject Matter Expert (SME) on DED metal technologies, with a near term emphasis on wire-based DED technologies and associated materials.
Responsible for AM application rapid development and rate production manufacturing workflow, qualification, implementation, and continuous improvement to enhance Quality / Yield, reduce Cost, and improve Productivity / Schedule.
Initiate and lead lean manufacturing process improvement projects.
Support manufacturing production planning and coordination, execution and operations process development.
Support and lead the planning and implementation of AM (incl. post-processing) supply chain, equipment and associated processes and safety.
Strategize, lead and execute development plans for novel DED convergent manufacturing systems applied to UAS structures.
Provide production support to internal stakeholders involved in the manufacturing processes associated with DED AM part production and post processing, including interfacing with external strategic suppliers.
Document manufacturing processes and assembly work instructions in conjunction with T&O Planning.
Development, review and/or modifications of AM DED specification documentation with key Materials & Process stakeholders.
Review engineering drawings, and provide expertise on metal DED during engineering review processes and support new DED application development and risk reduction activities.
Key interface with engineering stakeholders such as design, materials, process and quality.
Support and lead technology exploration, assessment and incubation.
Work closely with DfAM engineering on manufacturing/production operations, and assist with design engineering’s knowledge transfer and teaching efforts.
Disposition non-conforming parts, identify root cause analysis, and implement corrective and/or preventive action to reduce scrap and rework.
Collaboratively lead projects for new application development related to DED AM technologies.
Participation in internal and external AM group representation (e.g. conferences, collaboration groups, executive management reviews, etc.)
Collaborate with Design Engineering during development, prototype and first article manufacturing.
Support with metal DED AM supplier qualification, relationships and visits.
Support in growth strategy of metal DED AM within AM department and across GA divisions.