Metal Additive Manufacturing Designer/ModelerThis role is fully onsite in Bloomfield, CT, five days per week, and the company will be relocating to Suffield, CT later in 2026.
Position Overview:We are seeking a talented Engineer with a strong background in Additive Manufacturing and Topology Optimization to join our R&D team. In this role, you'll be responsible for transforming next-generation rotary engine designs through advanced computational design methods and manufacturing technologies. You'll work at the intersection of simulation, design, and manufacturing to push performance and efficiency beyond traditional boundaries. This is a hands-on, high-impact position with opportunities to invent, iterate, and deliver real-world solutions in a fast-paced development environment.
Key Responsibilities:- Apply topology optimization and additive manufacturing (AM) methods to design lightweight, high-performance engine components
- Use nTop (preferred) or similar software to optimize structural, thermal, and fluid-related features
- Develop and refine solid models and assemblies tailored for AM processes
- Collaborate with mechanical, thermal, and manufacturing engineers to integrate optimized parts into complete engine systems
- Analyze designs using simulations (FEA, CFD, thermal) and correlate with physical test data
- Oversee additive builds from design validation through manufacturing and post-processing
- Innovate new design approaches to improve performance, reduce weight, and streamline manufacturing
- Support engine testing and contribute insights based on material behavior and part performance
- Maintain clear documentation, share findings in presentations, and contribute to design reviews
- Uphold a proactive, problem-solving mindset with a collaborative and resilient approach to technical challenges
Required Qualifications:- BS or higher in Mechanical Engineering or related field
- 3+ years of professional experience in product design, simulation, and/or manufacturing
- Expertise in additive manufacturing methods (e.g., DMLS, SLS, Binder Jetting, etc.)
- Proficiency in topology optimization tools (nTop preferred) for structural, thermal, and fluid systems
- Strong 3D CAD skills (SolidWorks or equivalent)
- Simulation experience with ANSYS or similar FEA/thermal software
- Deep understanding of materials science, especially metallurgy as it pertains to AM
- Proven ability to work independently and solve complex, cross-disciplinary problems
Preferred Skills:- Experience with internal combustion engines, compressors, or advanced thermodynamic systems
- Knowledge of GT-Suite, MATLAB, Python, or other engineering simulation/scripting tools
- Experience in a prototype or R&D environment
- Strong written communication skills, including proposal and technical report writing
- Familiarity with quality control and inspection processes for additive parts
Benefits:- Flexible PTO to encourage work-life balance and personal well-being
- Comprehensive healthcare coverage: medical, dental, and vision plans
- Equity participation: RSUs for all permanent employees
- 401(k) with match: 100% up to 3%, plus 50% match for 3-5% range
- Growth opportunities: Mentorship, training, and leadership development
