As an integral member of the Advanced Materials Department, the successful candidate will balance multiple activities including but not limited to:
- Metallurgical and material science analysis and recommendations for multiple programs, guiding the successful use of additive manufacturing.
- Starting with a desired application, provide recommendations on AM technology and materials; perform trades on capability, cost, lead time, post processing, defects, deformation, expected material/component mechanical and thermal properties at both the microstructural and macro level.
- Developing plans and layouts for additive manufacturing equipment and capabilities
- Contributing to multiple program teams as the resident additive manufacturing expert across multiple metal additive technologies
- Design for additive manufacturing (DfAM)
Basic Qualifications
- Resident of North Alabama or willing to relocate to work on-site in Huntsville, AL.
- Experience in metallurgy/material science of additively manufactured materials
- Understanding of/ability to quantify expected material property outcomes based on microstructure and metallurgical mechanisms common in additively manufactured aerospace alloys
- Familiar with high strength/temperature metal alloys (nickels, HEAs, refractories, etc.)
- Hands-on experience with metal additive manufacturing engineering
- Experience with and basic understanding of design for additive manufacturing (DfAM), especially with Powder Bed Fusion, DED, and/or Cold Spray.
- Experience with metallurgical specimen preparation and inspection
- Bachelor's degree with a minimum 3.2 GPA in materials engineering, materials science, manufacturing engineering, or a related field from an ABET accredited university.
- 5+ years experience in metal additive manufacturing, or MS with 2+ years experience, or PhD with 1+ years experience
Preferred Qualifications
- Hands-on experience with the following metal additive manufacturing processes: Laser Powder Bed Fusion (LPBF), Cold Spray Additive Manufacturing, Directed Energy Deposition (DED), and Wire Arc Additive Manufacturing (WAAM)
- Hands on experience preparing mechanical testing, including monotonic, fatigue, creep, etc.
- Experience setting up metal builds with software like Materialise Magics, Oqton 3DXpert, EOSPrint, etc.
- Experience with metal additive manufacturing support structure design.
- Ability to support hardware systems including setup, operation, and troubleshooting of AM equipment.
- Experience with build parameter development, process development/optimization, and qualification.
- Familiarity with post-processing methods including heat treatment, machining, and surface finishing.
- Experience with simulation tools for additive manufacturing (thermal, distortion, support optimization).
- Exposure to in-situ monitoring systems or sensor integration in AM platforms.
- Programming or scripting experience (Python, MATLAB, or similar) for data analysis or workflow automation.
- Experience in communicating with external vendors or in contract manufacturing
- Experience obtaining quotes for work and equipment
- Experience writing proposals
- Design experience on SolidWorks, Creo, or other CAD systems
- Experience troubleshooting and maintaining complex AM equipment, including laser optics, process monitoring
- Experience working with hazardous materials
- Experience writing standard operating procedures and safety work practices documents
- Experience setting up AM equipment and training others on equipment
Original Posting:September 3, 2026
Pay Range:Pay Range $87,100.00 - $157,450.00
The Leidos pay range for this job level is a general guideline only and not a guarantee of compensation or salary. Additional factors considered in extending an offer include (but are not limited to) responsibilities of the job, education, experience, knowledge, skills, and abilities, as well as internal equity, alignment with market data, applicable bargaining agreement (if any), or other law.
