Sr. Manufacturing Development Engineer – Process

VulcanForms Inc.•Devens, MA

2d•$106,000 - $171,000

About The Position

As a Sr. Manufacturing Development Engineer - Process, you will own the end-to-end technical framework that translates customer designs into repeatable, high-performance physical products. You will bridge the gap between material science and high-volume digital production, overseeing the comprehensive process pipeline—including laser parameter optimization, print layouts, and post-printing thermal treatments. Success in this role means establishing stable, optimized processing windows that guarantee the mechanical, aesthetic, and metallurgical integrity of parts coming off our advanced production lines.

Requirements

5+ years of experience in process development, metallurgical engineering, or advanced materials processing within high-precision manufacturing (such as Metal Additive Manufacturing, Semiconductor fabrication, Aerospace processing, or advanced Injection Molding).
Proven ability to build and analyze statistical process control (SPC) data and DOEs to establish highly repeatable manufacturing windows.
Deep understanding of material behavior, thermal stress development, microstructural evolution, or mechanical testing protocols.
Bachelor’s or Master’s degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, Chemical Engineering, or a related technical discipline.
Analytical, structured problem solver with excellent cross-functional communication skills to translate complex processing data into actionable engineering workflows.

Responsibilities

Define, document, and optimize the comprehensive 3D digital manufacturing workflow, owning process intent from initial laser print files through stress-relief, heat treatment, and final part extraction.
Pioneer and refine high-temperature thermal recipes, laser interaction parameters, and advanced printing strategies to meet strict mechanical properties, surface finish requirements, and microstructural tolerances.
Design and execute complex Design of Experiments (DOE) using statistical software (such as Minitab or JMP) to analyze process capability ($C_p/C_pk}$), drive continuous yield improvements, and minimize scrap rates.
Lead technical investigations into failed builds, non-conformances, geometric distortions, and metallurgical variations, implementing robust corrective and preventive actions (CAPA).
Collaborate with Applications and Design teams on Design for Additive Manufacturing (DFAM) reviews, evaluating customer CAD geometries, support structures, and post-processing constraints to ensure stable manufacturability.