Sr. Staff Powder Factory Systems Engineer

VulcanForms Inc. • Devens, MA

1d • $147,000 - $203,000

About The Position

Architect, standardize, and scale VulcanForms’ powder production and factory systems by designing end-to-end powder handling, transfer, and safety architectures that enable safe, high-throughput, and cost-effective metal powder manufacturing at industrial scale.

Requirements

• 10+ years of experience designing and delivering industrial process, factory, or materials-handling systems in production environments.
• Demonstrated ownership of complex, safety-critical systems from concept through commissioning and sustained operation.
• Deep experience with powder or bulk solids handling systems, including conveying, classification, containment, and contamination control.
• Proven ability to lead system-level design decisions, balance competing requirements, and set technical direction across multidisciplinary teams.
• Strong background in hazard analysis and risk mitigation, with experience applying methods such as FMEA, or DHA to industrial systems.
• Track record of collaborating across engineering, operations, safety, quality, and facilities organizations to deliver production-ready systems.

Nice To Haves

• Direct experience designing, operating, or scaling metal powder atomization systems, including EIGA (Electrode Induction Gas Atomization) and/or VIGA (Vacuum Induction Gas Atomization).
• Hands-on experience working with reactive metal powders (e.g., titanium and titanium alloys), including inert gas handling, contamination control, and powder safety considerations.
• Experience engineering powder handling and transfer systems specifically for reactive or combustible metal dust environments, from atomizer discharge through packaging. Hands-on familiarity with combustible metal dust mitigation standards (e.g., NFPA 484, NFPA 652, OSHA).
• Familiarity with scaling powder production capacity while maintaining powder quality, yield, and safety margins.
• Experience deploying and scaling powder production or handling systems across multiple production lines or facilities.
• Proficiency creating and reviewing PFDs, P&IDs, material-flow models, and factory layout concepts.

Responsibilities

• Define the end-to-end architecture for powder transfer, handling, and storage systems across large-scale metal powder production facilities, from atomizer discharge through classification, storage, and packaging.
• Establish technical standards and design principles for powder flow performance, contamination control, segregation mitigation, safety, and throughput across VulcanForms’ powder ecosystem.
• Lead system-level engineering of powder production subsystems, including atomizer interfaces, catchment, classification, filtration, conveying, and collection architectures, with a focus on scalability and reliability.
• Own safety-critical system design for combustible metal dust environments, including inerting strategies, dust collection, explosion mitigation, interlocks, and regulatory compliance.
• Drive factory-level productivity by identifying bottlenecks, defining material-flow architectures, and engineering solutions that improve uptime, yield, ergonomics, and operational robustness.
• Provide technical leadership through equipment selection, vendor partnerships, FAT/SAT, commissioning, and plant startup, ensuring designs perform as intended in production.
• Establish reusable design frameworks, documentation, and best practices that enable consistent deployment across current and future VulcanForms facilities.

Benefits

• VulcanForms offers a competitive salary and equity package.
• Actual compensation is based on factors such as the candidate's skills, qualifications, and experience.
• 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 $147,000 to $203,000.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Education Level: No Education Listed