Bachelor's degree in Mechanical, Materials, Manufacturing, or Aerospace Engineering; Master's preferred.
3-7 years of experience in additive manufacturing or related engineering fields, preferably in aerospace or defense.
Proficient in Design for Additive Manufacturing (DfAM) principles and topology optimization.
Hands-on experience with metal and polymer AM systems and CAD/slicing tools.
Strong understanding of material properties and post-processing methods.
Familiarity with quality and inspection processes and standards like AS9100 or ISO 9001.
Demonstrated ability to analyze build data and maintain repeatable manufacturing outcomes.
Responsibilities
Collaborate with design engineers to identify suitable parts for additive manufacturing.
Apply DfAM principles to enhance efficiency and reduce post-processing needs.
Prepare 3D CAD models for printing, including orientation and support structure design.
Develop and refine AM process parameters for various materials.
Conduct build simulations to ensure high-quality parts.
Troubleshoot print failures by analyzing build data and machine performance.
Drive continuous improvement through data analytics and root-cause investigations.
Benefits
Opportunity to work on flight-critical and high-value parts.
Engagement in cutting-edge additive manufacturing technologies.
Collaborative environment with cross-functional teams.
Focus on continuous improvement and innovation.
Potential for involvement in R&D projects for performance optimization.
Full Job Description
Additive Manufacturing Engineer
Houston, TX
About the Position:
We are seeking an experienced Additive Manufacturing Engineer with hands-on expertise operating and optimizing EOS M290 Direct Metal Laser Sintering (DMLS) systems. This role combines engineering design, process development, and direct machine operation to ensure production of flight-critical and high-value parts. The ideal candidate is a problem-solver who thrives in a fast-paced environment and can bridge design, materials science, and production.
Responsibilities:
Collaborate with design and systems engineers to identify parts suitable for AM, ensuring manufacturability, weight reduction, and performance improvements.
Apply design-for-additive-manufacturing (DfAM) principles to enhance efficiency and reduce post-processing requirements.
Convert and prepare 3D CAD models for printing, including orientation, support structure design, and build parameter setup.
Develop, document, and refine AM process parameters for various materials (e.g., polymers, metals, composites).
Conduct build simulations and validate process settings to ensure repeatable, high-quality parts.
Troubleshoot print failures or quality issues by analyzing build data, material properties, and machine performance.
Drive continuous improvement through process characterization, data analytics, and root-cause investigations.
Operate and maintain additive manufacturing equipment (e.g., SLM, DMLS, FDM, SLA, or binder jet systems).
Monitor production schedules, coordinate builds, and manage printer utilization to meet project timelines.
Maintain machine calibration, preventive maintenance, and material handling procedures.
Ensure all builds comply with internal quality standards, certifications, and traceability requirements.
Develop and execute inspection plans for printed parts, including dimensional checks, surface finish, and material integrity testing.
Collaborate with Quality and Materials Engineering teams to establish acceptance criteria and validate process capability.
Research emerging AM technologies, materials, and post-processing methods to expand capabilities.
Lead or support internal R&D projects focused on lightweighting, performance optimization, or cost reduction.
Participate in supplier evaluations and technology roadmapping for additive manufacturing growth.
Analyze test results to drive design or process modifications.
Support qualification of AM parts for flight- or mission-critical applications where applicable.
Other duties as assigned.
General Requirements:
Bachelor's degree in mechanical, Materials, Manufacturing, or Aerospace Engineering required; master's preferred. •
3-7 years in additive manufacturing, advanced manufacturing, or related engineering discipline, ideally within aerospace, defense, or high-tech industries.
Proficient in Design for Additive Manufacturing (DfAM) principles, topology optimization, and lightweighting for performance and cost efficiency.
Hands-on experience with metal and polymer AM systems (SLM, DMLS, EBM, FDM, SLA) and CAD/slicing tools (SolidWorks, NX, Magics, EOSPRINT, GrabCAD).
Strong understanding of material properties, metallurgy, and post-processing methods such as heat treatment, machining, and surface finishing.
Familiarity with quality and inspection processes (CT scanning, CMM, NDT) and standards such as AS9100 or ISO 9001.
Demonstrated ability to analyze build data, identify process improvements, and maintain repeatable manufacturing outcomes. (ANSYS)
Experienced in cross-functional collaboration with design, quality, and production teams to transition parts from prototype to production.
Excellent communication, documentation, and project coordination skills in fast-paced, multidisciplinary environments.
Innovative mindset with a strong commitment to continuous improvement, data-driven problem solving, and operational excellence.
