Senior PBF Development Engineer
About The Position
The Powder Bed Fusion Additive Manufacturing team is pushing the boundaries of what's possible in rocket propulsion hardware. Responsible for development, process, and production, the team oversees initial concept to final hardware with rigorous quality and precision. From developing print parameters on state-of-the-art 3D printers to enabling fast iteration for partner departments, the team plays a critical role in taking engine designs from concept to hot fire. The team was instrumental in producing Aeon 1 engines for Terran 1 launch and is now pioneering next-generation processes and designs for our Aeon R engines that will power Terran R. With flight hardware production scaling up rapidly, now is the time to join and make a direct impact. The Senior PBF Process Control Engineer owns the core PBF process definition for Relativity's metal additive production systems. You will drive qualification strategies, parameter management, and process stability frameworks across flight hardware production. You will partner closely with M&P, Quality, PBF Development and Production to define how process changes are evaluated and verified, and ensure our specifications stay ahead of design and vehicle demands.
Requirements
- B.S. or M.S. in Mechanical, Materials, Aerospace, or Manufacturing Engineering
- 5 + years of industry experience in metal AM process control (or hardware ownership) or special process ownership in aerospace
- Strong understanding of metal AM qualification and material property verification strategies
- Demonstrated experience with controlled specification management and configuration control tools
- Proven ability to analyze test data and draw statistically sound conclusions for process acceptance
- Experience with EOS and Velo hardware and EOSPRINT/Flow software
Nice To Haves
- Familiarity with Process Control Documents and NASA/DoD metal AM qualification standards
- Experience mentoring junior engineers and leading cross-functional investigations
- Working knowledge of SQL/Python data pipelines and SPC dashboards
- Demonstrated impact in reducing process variability or establishing stable production capability
Responsibilities
- Lead authorship and stewardship of controlled PBF process specifications (powder reuse, parameter sets, machine maintenance, post-processing, test requirements)
- Own the Process Change Verification workflow - define qualification strategy, build test plans, execute data review and acceptance criteria for new parameter sets, materials, or equipment
- Develop statistical frameworks for process capability (Cpk, tensile variability, powder lifecycle metrics)
- Lead root cause and corrective action efforts for PBF-related non-conformances
- Guide junior engineers in process documentation, data interpretation, and verification test design
- Represent the PBF organization in cross-functional reviews (e.g., Material Review Board, Design Change Board, Qualification Readiness Reviews)
- Drive risk reduction initiatives - parameter validation across machines, environmental controls, powder degradation tracking, and build stability optimization
- Collaborate with Design and M&P on allowable generation and witness coupon strategy to ensure flight margin confidence
- Partner with Quality and Production to streamline AS9100 compliance and data traceability frameworks
- Support hardware failure analysis and lessons-learned integration into process specifications
- Hardware ownership - creating process plans, work orders, and dispositioning non conformances
- Working with Designers on DFAM input
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What This Job Offers
Job Type
Full-time
Career Level
Mid Level
Industry
Transportation Equipment Manufacturing
Number of Employees
1,001-5,000 employees
