Sr. Applications Development Engineer

VulcanForms-posted 25 days ago
$97,600 - $134,200/Yr
Full-time • Mid Level
Onsite • Devens, MA
101-250 employees
Professional, Scientific, and Technical Services
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As a Sr. Applications Development Engineer at VulcanForms, your mission is to design and optimize our high-speed laser-powder-bed-fusion process and its digital workflow to deliver production-ready parts at scale. You'll collaborate across hardware, software, and operations teams to continuously improve print quality, system reliability, and workflow efficiency - enabling transformative outcomes for our customers and the future of advanced manufacturing.

  • Partner with hardware, software and operations teams to develop and implement integrated process - from R&D through pilot runs to full serial production - achieving high manufacturing readiness levels.
  • Create and iterate LPBF process recipes and build configurations, including build files, post-process sequences, and machine integration to ensure consistent production of parts within the VulcanForms platform.
  • Translate user requirements into engineering specifications that guide end-to-end product and process development; collaborate with internal teams to optimize part designs for LPBF, balancing geometry, supports, tolerances and material performance.
  • Build and iterate parts, hardware, and tools to support First Article Inspection and production launches of products in medical, aerospace, consumer, defense, and other industries.
  • Serve as the technical interface with customers, program managers, and operations leaders - communicating development status, sharing findings, troubleshooting issues, and aligning on production plans.
  • Own root cause analysis of print defects and drive corrective actions through rapid iteration and testing.
  • Develop application-specific process workflows that meet customer requirements for dimensional accuracy, mechanical performance and surface finish.
  • Collaborate with downstream process owners in machining, finishing, and other areas to implement DFM principles with a top-down approach.
  • Collaborate with operations and quality teams to establish standard operating procedures and quality control methods.
  • Create and maintain detailed documentation: build recipes, work instructions, inspection protocols, change logs and training materials - ensuring repeatability, traceability and production compliance.
  • Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a related field; Master's or Ph.D. preferred.
  • Minimum of 2 years hands-on experience in product or applications development, preferably with a focus on LPBF or directed energy deposition (DED) processes.
  • Proficiency in 3D CAD software such as Siemens NX, Creo, or SolidWorks.
  • Solid understanding of GD&T, tolerance analysis, and design for manufacturability (DFM) principles.
  • Familiarity with quality management systems and associated standards.
  • Strong interpersonal and communication skills with the ability to collaborate effectively across multidisciplinary teams.
  • Knowledge of subtractive manufacturing operations (e.g. milling, turning) and their design constraints is a plus.
  • VulcanForms offers a competitive salary and equity package.
  • In addition, VulcanForms provides comprehensive benefits including medical, dental, vision, and life insurance; generous paid time off; and a 401(k) plan with company match.
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