Senior Process Engineer, Additive Manufacturing
About The Position
Rennscot MFG is seeking an industry-experienced, hands-on senior engineer with direct metal additive manufacturing experience. The engineer will own the metallurgical test lab, lead material and process qualifications across multiple alloy systems, and work with AM equipment, materials, engineering, quality, and production teams to solve technical challenges and establish reliable manufacturing processes. The role involves taking the internal test lab from concept to day-to-day operation, including equipment selection and qualification, establishing test methods and procedures, developing calibration and maintenance requirements, and training staff. Lab capabilities will include particle size distribution, porosity characterization, mechanical testing, and microstructural analysis. The engineer will develop and execute material and process qualifications for stainless steel, nickel, titanium, aluminum, and other alloy systems. This includes working directly with AM processes and equipment to establish parameters, run trials, evaluate results, and qualify processes to customer and industry requirements, including AMS, ASTM, and SAE standards. The position also investigates manufacturing issues using metallurgical analysis, process data, structured experimentation, and hands-on investigation; leads qualifications from planning through execution, including IQ/OQ/PQ activities, DOE-based studies, process-window development, validation testing, documentation, and technical reporting; and partners with engineering, quality, and production to translate metallurgical requirements into shop-floor processes. The engineer will help establish build and validation documentation in ProShop ERP, develop practical team training, and identify ways to improve material qualification, process validation, result evaluation, and technical problem-solving as the company’s AM business grows. The position is on-site in Woburn, Massachusetts. Applicants must be within a 100-mile radius; relocation assistance is not provided. To conform to U.S. export regulations, applicants must be U.S. citizens, lawful permanent residents, protected individuals as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain required authorizations from the U.S. Department of State.
Requirements
- Direct, hands-on experience with metal additive manufacturing processes such as laser powder bed fusion, DED, or binder jetting.
- Experience developing, qualifying, or improving AM materials and manufacturing processes in an industrial environment.
- Practical experience troubleshooting AM builds, material issues, defects, or process variation.
- Hands-on metallurgical testing experience, including microstructural analysis, porosity, mechanical testing, and/or powder characterization.
- Experience working with stainless steel, nickel, titanium, aluminum, or similar alloy systems.
- Experience executing process or equipment qualification, including IQ/OQ/PQ or comparable validation methodologies.
- Working knowledge of AMS, ASTM, SAE, customer specifications, or similar manufacturing standards.
- Experience using DOE, statistical analysis, and process data to make manufacturing decisions.
- Ability to translate metallurgical principles, including solidification, phase transformations, microstructure, and defect formation, into practical process decisions.
- Experience documenting qualification activities, test results, technical findings, and recommendations suitable for internal and customer review.
- Experience thresholds by education: 12+ years with a high school diploma, 10+ years with an associate degree, 5+ years with a bachelor's degree, 3+ years with a master's degree, or a Ph.D.
- Must be a U.S. citizen, lawful permanent resident, protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain required U.S. Department of State authorizations under ITAR.
Nice To Haves
- A bachelor's or master's degree in metallurgical engineering, materials science, or a closely related field is preferred.
- Experience standing up or operating a metallurgical lab.
- Experience working in aerospace or another highly regulated manufacturing environment.
- Experience qualifying AM processes for production applications.
Responsibilities
- Build and operate the metallurgical test lab, including selecting and qualifying equipment, establishing test methods and procedures, setting calibration and maintenance requirements, and training users.
- Develop and execute material and process qualifications for stainless steel, nickel, titanium, aluminum, and other alloy systems.
- Work directly with AM processes and equipment to establish parameters, run trials, evaluate results, and qualify processes to customer and industry requirements, including AMS, ASTM, and SAE standards.
- Investigate manufacturing problems involving builds, materials, test results, defects, or process variation; identify root causes and implement corrective actions.
- Lead qualification efforts from planning through completion, including IQ/OQ/PQ activities, DOE-based studies, process-window development, validation testing, documentation, and technical reporting.
- Manage multiple qualification efforts and drive them through completion.
- Collaborate with engineering, quality, and production to translate metallurgical requirements into practical shop-floor processes.
- Help establish build and validation documentation in ProShop ERP and develop practical training for the team.
- Identify improvements to material qualification, process validation, result evaluation, and technical problem-solving as the additive manufacturing business grows.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
Education Level
No Education Listed
