Additive Manufacturing EngineerHouston, 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.
