SR.MFG PROCESS DEVELOPMENT ENGINEER, CO

SR. MANUFACTURING PROCESS DEVELOPMENT ENGINEER, CONSUMER TECHNOLOGY - $106,000 TO $146,000 ANNUALLY VulcanForms develops industrially scalable laser metal additive manufacturing technology for aerospace, defense, medical, consumer, and other critical industries. Through advanced additive manufacturing, precision machining, software, automation, and operations expertise, we deliver end-to-end production at scale. About the Role: As a Sr. Manufacturing Process Development Engineer, Consumer Technology, you will own the end-to-end technical framework that translates customer designs into repeatable, high-performance physical products for VulcanForms? consumer-technology business. You will connect materials science with high-volume digital production while overseeing the complete process pipeline, including laser parameter optimization, print layouts, thermal treatments, and final part extraction. Success in this role requires establishing stable, optimized processing windows that ensure the mechanical, aesthetic, and metallurgical integrity of parts produced on advanced manufacturing lines. Key Responsibilities: - Define, document, and optimize the complete 3D digital manufacturing workflow - Own process intent from initial laser print files through stress relief, heat treatment, and final part extraction - Develop and refine high-temperature thermal recipes, laser interaction parameters, and advanced printing strategies - Optimize processes to meet strict mechanical property, surface finish, and microstructural requirements - Design and execute complex Design of Experiments using statistical software such as Minitab or JMP - Analyze process capability data to drive continuous yield improvements and reduce scrap - Lead technical investigations into failed builds, nonconformances, geometric distortion, and metallurgical variation - Develop and implement robust corrective and preventive actions - Partner with Applications and Design teams on Design for Additive Manufacturing reviews - Evaluate customer CAD geometries, support structures, and post-processing constraints - Help ensure stable, repeatable manufacturability across production workflows - Translate complex process data into practical engineering standards and manufacturing instructions Qualifications: - 5+ years of experience in process development, metallurgical engineering, or advanced materials processing - Experience in high-precision manufacturing, such as metal additive manufacturing, semiconductor fabrication, aerospace processing, or advanced injection molding - Proven ability to develop and analyze statistical process control data - Demonstrated experience designing and analyzing Design of Experiments - Ability to establish highly repeatable manufacturing process windows - Deep understanding of material behavior, thermal stress development, microstructural evolution, or mechanical testing protocols - Bachelor?s or Master?s degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, Chemical Engineering, or a related technical discipline - Strong analytical and structured problem-solving skills - Excellent cross-functional communication skills - Ability to translate complex processing data into actionable engineering workflows Preferred Qualifications: - Direct experience with laser metal powder bed fusion or other metal additive manufacturing processes - Experience developing laser parameters, print strategies, thermal recipes, or post-processing conditions - Familiarity with Minitab, JMP, or comparable statistical analysis software - Experience with Design for Additive Manufacturing, CAD-based manufacturability reviews, and support-structure development - Experience with nonconformance investigations, root cause analysis, and CAPA implementation - Experience supporting high-volume or consumer-product manufacturing environments