Processing Engineer III, Additive Manufacturing

Rennscot MFG • Woburn, MA

3d • $105,000 - $140,000 • Onsite

About The Position

We are looking for an engineer with deep metallurgical expertise to help build and lead a critical part of our additive manufacturing program. This is a hands-on technical role with real ownership — you will stand up and run our metallurgical test lab, lead process and material qualification across multiple alloy systems, and help set the technical direction for how we approach additive manufacturing quality. If you are someone who solves hard problems, follows through on what you commit to, and takes pride in building things that work — this role is worth a look.

Requirements

• 12+ years (H.S. Diploma) | 10+ years (A.A.) | 5+ years (Bachelor's) | 3+ years (Master's) | Ph.D.
• A bachelor's or master’s in metallurgical engineering, materials science, or a closely related field is preferred.
• Your experience should include expert-level metallurgical and materials testing, hands-on process qualification on metal AM platforms (laser powder bed fusion, DED, or binder jetting), and direct experience with stainless, nickel, titanium, and aluminum alloy systems.
• Experience standing up or operating a metallurgical lab and leading IQ/OQ/PQ activities in a regulated environment (aerospace, medical device, or similar) is strongly preferred.
• Expert-level knowledge of metallurgical testing: PSD, porosity, mechanical testing, and microstructural analysis
• Hands-on experience with metal AM process and material qualification to AMS, ASTM, or SAE standards
• Proficiency with advanced metrology instruments and quality systems
• Strong DOE and statistical process control skills
• Deep understanding of metallurgical principles — phase transformations, solidification behavior, defect formation — as they apply to AM alloy systems
• Strong technical writing skills; able to produce qualification procedures and test reports that hold up to internal and customer review

Nice To Haves

• Experience contributing to external technical forums, publications, or industry groups is an asset

Responsibilities

• Build and run our metallurgical test lab. You will take our test lab from concept to full operation — selecting and qualifying equipment, establishing procedures, setting calibration schedules, and training the team on how to use it. Testing capabilities will include particle size distribution, porosity characterization, mechanical testing, and microstructural analysis. You will also have input to lab's long-term capability roadmap, keeping an eye on emerging technologies and methods.
• Lead process and material qualification. You will develop and execute qualification procedures for stainless steel, nickel, titanium, and aluminum alloys to both customer and industry standards (AMS, ASTM, SAE, and others). This includes leading IQ/OQ/PQ activities for AM equipment, running structured experiments and DOE-based studies to validate process windows, and performing root-cause analysis when things go wrong. You will manage multiple qualification projects simultaneously and deliver on your commitments.
• Work across teams. You will connect the dots across engineering, quality, and operations — bringing people together to solve problems, share knowledge, and keep AM initiatives moving forward. You will govern build and validation documentation standards in ProShop ERP, and help develop structured training.
• Innovate. You will find better ways to qualify additively manufactured parts and build processes that expand what our team can do. This means work that shapes industry practice, not just internal practice.

What This Job Offers

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