Senior Process Engineer

VulcanForms Inc.•Devens, MA

3d•$106,000 - $146,000

About The Position

As a Senior Process Engineer, you will play a pivotal role on the core engineering team defining 3D printing processes for our major production programs. Your main objective will be to design, develop, optimize, and implement scalable manufacturing processes for industrial applications utilizing our advanced metal additive manufacturing (AM) systems. You will define process strategies for customer programs, conduct printing experiments, and analyze outcomes to bridge the gap between initial design and mass production. Collaborating closely with cross-disciplinary experts in machinery, software, controls, and materials, you will continuously improve process capabilities. Your work will directly enable the mass production of high-performance parts that meet or exceed rigorous internal and industrial quality standards. Additionally, you will be responsible for defining project deliverables, managing execution, documenting progress, and communicating milestones with leadership and program stakeholders.

Requirements

5+ years of industrial experience in Mechanical Engineering, Aerospace Engineering, Materials Science, or a related technical field.
Strong background in advanced manufacturing, thermal processes, or industrial laser applications (e.g., laser welding, cladding, heat treating, or additive manufacturing).
2+ years of hands-on experience in industrial process development, optimization, and scaling.
Practical understanding of materials/metallogy (steel, aluminum, titanium, or nickel alloys) and familiarity with data analysis tools for process optimization.
Experience utilizing CAD software (Creo, Autodesk Inventor, SolidWorks) or engineering tools to interface with manufacturing systems.

Responsibilities

Develop, execute, and analyze process parameters and methodologies to support specific program requirements and scale them for mass production.
Define and implement process development strategies and roadmaps for advanced metal AM systems, aligning machine capabilities with program goals.
Apply data-driven approaches to evaluate machine configurations, process data, geometry, and post-print inspections to build a comprehensive database of process capabilities and limitations.
Partner with hardware, software, controls, and materials teams to provide first-hand feedback on system performance, feature implementation, and operational reliability.
Stay informed of industry trends and cutting-edge solutions in advanced manufacturing and process engineering to drive continuous optimization.