Principal Additive Process Engineer (Onsite)

RTX

79d • $101,000 - $203,000

About The Position

At Collins Aerospace, we’re redefining what’s possible in advanced manufacturing — and additive technology is at the forefront of that transformation. As a Principal Additive Process Engineer, you’ll serve as the technical authority for additive manufacturing (AM) processes and technologies at our site. You will drive the development, qualification, and continuous improvement of additive processes that deliver high-quality, flight-critical components for both military and commercial aerospace applications. This is a hands-on, strategic engineering role that requires deep technical expertise, cross-functional collaboration, and a passion for pushing the boundaries of what additive manufacturing can achieve.

Requirements

• Typically requires a degree in Science, Technology, Engineering or Mathematics (STEM) and minimum 8 years prior relevant experience or an Advanced Degree in a related field and minimum 5 years of experience.

Nice To Haves

• Hands-on experience with metal additive manufacturing processes, preferably powder bed fusion (e.g., EOS, Renishaw, SLM Solutions, or equivalent systems).
• Strong knowledge of process development, qualification, and control within a regulated manufacturing environment.
• Experience in aerospace or defense manufacturing and familiarity with industry standards for additive qualification and certification.
• Background in data systems integration (MES, QMS, or automated data capture tools).
• Demonstrated ability to lead root cause analysis and drive corrective/preventive action.
• Working experience with Design for Additive Manufacturing (DfAM) and process simulation tools.

Responsibilities

• Lead the development, optimization, and sustainment of powder bed fusion (PBF) processes across multiple machines, materials, and part families.
• Serve as the process owner for AM technologies — ensuring consistent, high-quality production that meets stringent aerospace standards.
• Manage and execute Operational Qualifications (OQ) for PBF machines resulting from process changes, upgrades, or repairs.
• Review and approve slice files, machine calibration data, and build records to ensure compliance with OQ and product qualification requirements.
• Conduct process capability studies for dimensional accuracy and mechanical properties across the additive and post-processing workflow (depowdering, heat treat, etc.).
• Develop and maintain PFMEAs, control plans, and standardized documentation to ensure robust and repeatable production processes.
• Establish data acquisition systems and analytics frameworks to monitor key process inputs/outputs and define data-driven control limits.
• Apply deep understanding of process–microstructure–property relationships to lead root cause investigations and implement corrective actions.
• Partner with Design, Manufacturing, Quality, and Materials Engineering teams to ensure additive designs are producible and optimized for performance.
• Contribute to and help execute the long-term additive manufacturing technology roadmap, driving continuous improvement and cost competitiveness.

Benefits

• Medical, dental, and vision insurance
• Three weeks of vacation for newly hired employees
• Generous 401(k) plan that includes employer matching funds and separate employer retirement contribution, including a Lifetime Income Strategy option
• Tuition reimbursement program
• Student Loan Repayment Program
• Life insurance and disability coverage
• Optional coverages you can buy pet insurance, home and auto insurance, additional life and accident insurance, critical illness insurance, group legal, ID theft protection
• Birth, adoption, parental leave benefits
• Ovia Health, fertility, and family planning
• Adoption Assistance
• Autism Benefit
• Employee Assistance Plan, including up to 10 free counseling sessions
• Healthy You Incentives, wellness rewards program
• Doctor on Demand, virtual doctor visits
• Bright Horizons, child and elder care services
• Teladoc Medical Experts, second opinion program
• And more!

What This Job Offers

• Job Type: Full-time
• Career Level: Senior
• Education Level: Bachelor's degree
• Number of Employees: 5,001-10,000 employees