Principal Process Engineer, LPBF

Beehive Industries • Knoxville, TN

2d

About The Position

The Principal Additive Process Manufacturing Engineer serves as a recognized technical authority responsible for advancing Laser Powder Bed Fusion (LPBF) technology, materials, and production capabilities for critical aerospace and defense applications. The role provides expert-level leadership in additive manufacturing process development, metallurgy, and production scale-up while influencing technical strategy and manufacturing innovation. It drives solutions to complex technical challenges and establishes best practices for reliable, high-performance additive manufacturing operations.

The position leads LPBF process and materials development, production readiness, process qualification and validation, and continuous improvement. It establishes technical strategies and roadmaps, develops production-ready processes, and improves standards, specifications, process controls, and documentation. The role also guides cross-functional teams, mentors engineers, supports decisions about equipment and future technologies, and represents additive manufacturing expertise in reviews with leadership, customers, suppliers, and industry partners. Other duties may be assigned.

Requirements

• Bachelor’s degree in Engineering, Metallurgy, Materials Engineering, Mechanical Engineering, or a related technical field, or an equivalent combination of education and experience.
• Minimum of 12 years of experience in additive manufacturing, LPBF process development, metallurgy, materials engineering, or related manufacturing disciplines.
• Extensive experience developing, optimizing, and scaling additive manufacturing processes for production applications.
• Demonstrated experience serving as a technical leader on complex engineering programs and manufacturing initiatives.
• Experience supporting aerospace, defense, or other highly regulated manufacturing environments.
• Expert knowledge of LPBF systems, additive manufacturing processes, and production implementation strategies.
• Deep understanding of powder metallurgy, material behavior, laser-material interactions, melt pool dynamics, and thermal management.
• Advanced experience with process parameter development, powder characterization, defect analysis, and process optimization.
• Ability to establish technical direction and solve complex engineering challenges with significant organizational impact.
• Experience developing manufacturing standards, process specifications, and qualification strategies.
• Strong understanding of process control, experimental design (DOE), data analysis, and manufacturing validation methods.
• Ability to influence cross-functional teams and communicate complex technical concepts to technical and executive audiences.
• Demonstrated ability to mentor engineers and elevate technical capabilities within an organization.
• Ability to obtain and maintain a U.S. government-issued security clearance; U.S. citizenship is required because only U.S. citizens are eligible for a security clearance.

Nice To Haves

• Master’s degree or PhD in Engineering, Metallurgy, Materials Engineering, or a related field.
• Experience leading production LPBF implementation for aerospace or defense applications.
• Expertise in laser optics, sensors, in-situ monitoring, and additive manufacturing process control systems.
• Experience with additional additive manufacturing technologies, including EBM, DED, or binder jet.
• Familiarity with investment casting, machining, and hybrid manufacturing strategies.
• Experience leading additive manufacturing technology transitions from research and development through production scale-up.
• Experience contributing to patents, publications, technical presentations, or industry standards.
• Experience influencing manufacturing strategy, capital investments, and long-term technology roadmaps.

Responsibilities

• Serve as a technical authority for LPBF additive manufacturing processes, materials development, and production readiness initiatives.
• Define technical strategies and roadmaps for additive manufacturing capabilities, process optimization, and production scalability.
• Lead development and implementation of advanced LPBF process parameters for complex materials and geometries.
• Establish and improve additive manufacturing standards, specifications, process controls, and technical documentation.
• Resolve complex challenges related to powder metallurgy, laser-material interaction, melt pool behavior, thermal management, and part performance.
• Lead development of production-ready additive manufacturing processes, including qualification, validation, and continuous improvement.
• Apply expertise in metallurgy and additive manufacturing to optimize material properties, reduce defects, and improve manufacturing performance.
• Influence integration of LPBF into broader manufacturing workflows, including post-processing, machining, inspection, and quality systems.
• Guide cross-functional engineering teams in solving complex technical problems and advancing additive manufacturing capabilities.
• Mentor engineers and provide technical leadership across additive manufacturing initiatives.
• Support strategic decisions related to equipment capabilities, process improvements, and future manufacturing technologies.
• Represent additive manufacturing expertise in technical reviews with leadership, customers, suppliers, and industry partners.
• Perform other duties as assigned.

Benefits

• Group medical coverage from day one.
• Dental coverage from day one.
• Life insurance from day one.
• Short- and long-term disability coverage from day one.
• 401(k) retirement savings plan with company match.
• Bonus eligibility for every role.
• Equity in the company.

What This Job Offers

• Job Type: Full-time
• Career Level: Principal