Metal Additive Manufacturing Programming & Process Engineer
About The Position
The Additive Programming & Process Engineer connects digital build preparation, Laser Powder Bed Fusion (LPBF), precision machining, and inspection to deliver repeatable, production-ready metal components. This hands-on role develops build strategies and manufacturing processes and works with engineering, technicians, machinists, quality, and customers to improve part quality, cost, and delivery. CNC programming or machining experience is preferred. The role reviews customer CAD models, drawings, and specifications; prepares build jobs and manufacturing requirements; develops and validates LPBF build strategies; and supports builds, production troubleshooting, post-processing, machining, inspection, and process qualification. It also maintains controlled build files, documentation, parameter records, and traceable production histories while following approved safety, material-handling, contamination-control, and change-control procedures. The position is based in Shelton, Connecticut. Applicants must be U.S. citizens, lawful permanent residents, or protected individuals as defined by ITAR (22 CFR §120.15).
Requirements
- Degree in mechanical engineering, manufacturing engineering, materials science, or a related field, or equivalent technical education and relevant practical experience.
- Hands-on experience in metal LPBF build preparation and production support, with practical manufacturing problem-solving skills.
- Proficiency with 3D CAD, engineering drawings, GD&T, and revision-controlled documentation.
- Knowledge of metallurgy, thermal processing, distortion control, LPBF process variables, and common defects.
- Experience with design of experiments, statistical process control, quality systems, first-article inspection, and transition to repeat production.
- Experience maintaining digital build libraries, parameter revision tracking, and traceable build histories for quality audits.
- Must be a U.S. citizen, lawful permanent resident of the U.S., or protected individual as defined by ITAR (22 CFR §120.15).
Nice To Haves
- CNC programming, setup, or machining experience, including machining allowances, datums, fixturing, and finishing of additively manufactured parts.
- Mastercam experience.
- Experience with AM build-preparation tools, OEM slicing software, and thermal/mechanical build simulation.
- SolidWorks experience.
Responsibilities
- Review customer CAD models, drawings, and specifications; prepare or repair models and define build requirements, machining allowances, and manufacturing risks.
- Configure and slice build jobs, optimizing part orientation, nesting, and support structures to balance thermal dissipation, residual stress, distortion, build-plate utilization, and ease of post-processing.
- Develop laser vector and scan strategies, including contouring, striping, or checkerboard approaches, and select approved parameter sets for part geometry, mechanical properties, and surface finish.
- Validate parameter changes and obtain approval before using them in production.
- Use digital build simulation, where available, to assess thermal stress, deformation, and recoater interference and resolve risks before releasing builds.
- Deliver verified build files, setup sheets, and controlled work instructions; confirm revisions, materials, approved parameters, and machine readiness with production technicians.
- Support first builds and production troubleshooting through structured trials, build-data analysis, and root-cause investigation; improve yield, repeatability, throughput, and finished-part cost.
- Coordinate powder traceability, heat treatment, support removal, wire EDM, finishing, and CNC machining, as applicable.
- Collaborate on datums, workholding, machining access, and inspection requirements.
- Partner with quality on inspection plans, material testing, first-article activities, and process qualification.
- Maintain build libraries, parameter revisions, build histories, and engineering/ERP records.
- Communicate technical issues and production priorities, guide operators, and follow approved safety, material-handling, contamination-control, and change-control procedures.
- Perform other related duties as assigned.
Benefits
- Health, dental, life, and vision insurance
- 401(k) with match and profit sharing
- Annual bonus based on division profitability
- Vacation and flexible paid holidays
- Wellness and Employee Assistance Programs
- Tuition reimbursement and paid training
- Work with an established team of long-term employees
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What This Job Offers
Job Type
Full-time
