Senior Process Engineer, Additive

As a Senior Product Engineer, Additive at VulcanForms, you will design and direct the manufacturing processes within our Industrials business unit that take customer designs and translate them into printable repeatable production processes. You will work on new product introduction and on continuous improvement of parts already in production. You will use advanced manufacturing techniques, automation, and lean manufacturing methods to develop an optimized production part. You will define the processes, procedures, work instructions, and systems that produce our components and sub-assemblies to customer specification, drawing on product design, fabrication, assembly, work-holding, cutting tools, and materials expertise. You will support a wide range of energy, industrials and firearms products. There may be additional travel as needed to our facility in Devens, MA. Key Responsibilities: Evaluate customer designs and provide Design for Additive Manufacturing (DFAM) feedback. Synthesize technical requirements to support with cost estimation, technical risk assessment, and development timelines. Partner with the rest of the product team to make sure processing intent is optimized for customer requirements. Own process development for all print set up and printing operations including materials properties development, simulation analysis, layout optimization, support structure design and stock additions. Work with quality resources to ensure appropriate inspection techniques are employed, and are meeting customer needs in both a development, and production context. Support with development of design documentation necessary to support the manufacturing process including manufacturing specs, solid models and drawings. Write and maintain work instructions and process-related quality documentation, adapting existing processes for new products and keeping files, programs, and revisions under proper configuration control. Support operations with troubleshooting and problem-solving for all printing processes. Qualifications: 4+ years of progressive, hands-on experience in product or applications development in LPBF or similar additive technology. Bachelor's degree in Mechanical, Materials, Aerospace, Biomedical Engineering, or a related field preferred. Expert-level proficiency in advanced 3D CAD software (e.g., Siemens NX, Creo, SolidWorks) including 3D printing build-preparation tools (e.g., Magics, nTopology, Amphyon). Deep mastery of GD&T, advanced statistical process capability, tolerance stack-up analysis, and complex DFM/DfAM constraints. Experience using ERP systems in a batch manufacturing process. Strong working knowledge of subtractive manufacturing operations (5-axis milling, turning, EDM) and their integration with additive workflows is preferred.