Sr. Manager, Simulation Engineering
About The Position
The Sr. Manager of Simulation Engineering leads a high-performing team that defines and executes the enterprise simulation strategy for Laser Powder Bed Fusion (LPBF) metal additive manufacturing at Vulcanforms. This role owns the long-term roadmap for digital thread enablement and provides the technical leadership needed to develop, validate, and industrialize high-fidelity simulation models, both physics-based and data-driven. In this role, you will bridge process engineering, materials science, multiphysics modeling, computational engineering, and manufacturing systems integration to enable predictive, scalable, production-grade digital manufacturing.
Requirements
- 10+ years of experience with commercial FEA solvers (e.g., Ansys, Abaqus, Simufact, Netfabb) and Python-based automation for simulation.
- Experience developing simulation tools for production environments.
- 5+ years in Additive Manufacturing simulation.
- Master's or PhD in Mechanical Engineering, Materials Science, or Computational Physics.
- Proven experience in nonlinear structural analysis, thermal-mechanical coupling, and residual stress prediction.
- Strong understanding of modeling and simulation codes along with methods development in high-performance computing environments.
- Proven ability to build, lead, and energize cross-functional teams on high-impact technical projects.
Nice To Haves
- Experience with commercial simulation tools, physics-based modeling, numerical methods, or computational science to guide technical strategy.
- Experience with 3D printing / LPBF OEM systems.
- Understanding of Ti-6Al-4V, IN 718 & 625, and AlSi10Mg material behavior in LPBF.
- Background in aerospace or medical device qualification standards.
- Ability to translate complex computational results into clear business strategies for cross-functional teams.
Responsibilities
- Define and execute the long-term roadmap for a simulation-enabled digital thread across design, build preparation, process execution, and post-processing.
- Own the strategic vision for the "Simulation-to-Print" pipeline, ensuring seamless integration of high-fidelity simulation solvers into production while balancing short-term needs with long-term strategic objectives.
- Develop KPIs for simulation accuracy, cycle time reduction, yield improvement, and qualification acceleration.
- Provide hands on technical direction in multiphysics modeling including transient heat transfer, thermo-mechanical stress and distortion, powder spreading and recoating, melt pool dynamics, and solidification
- Improve simulation runtime to production-feasible levels, developing scalable workflows for batch part processing, enabling automated support generation and compensation strategies, and implementing distortion compensation and predictive shrinkage correction.
- Oversee simulation software architecture and define APIs and data standards for seamless integration across the digital thread.
- Work cross-functionally to identify, scope, and prioritize high-impact simulation opportunities across the organization.
- Build and mentor a multidisciplinary simulation team by establishing best practices and fostering a culture of technical rigor, data-driven decision-making, and rapid iteration.
- Stay current with the latest advancements in additive manufacturing process modeling, simulation methodologies, compensation strategies, and process control.
Benefits
- 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.
- The annual base salary range for this position is $200,000 to $276,000.
Stand Out From the Crowd
Upload your resume and get instant feedback on how well it matches this job.
What This Job Offers
Job Type
Full-time
Career Level
Manager
Number of Employees
11-50 employees
