Advanced Process Engineer (Metal AM)

Location: Centennial, Colorado, United States. The role is subject to ITAR and EAR requirements; applicants must be U.S. citizens, lawful permanent residents, protected individuals, or eligible to obtain the required authorizations.

Base salary: $125,000–$168,000 at P3, $139,000–$187,000 at P4, or $153,000–$205,000 at P5.

Company

Develops Superpower industrial gas turbines for behind-the-grid energy generation and Symphony supersonic aircraft engines using high-temperature nickel superalloys.

What you will do

• Design and execute DOEs for difficult-to-print alloys on production LPBF machines.
• Develop process parameters from scratch for extreme-preheat platforms and crack-prone superalloys.
• Own part-specific application development, including build orientation, supports, distortion compensation, depowdering, heat treatment, HIP, machining interfaces, and inspection plans.
• Automate DOE generation and build preparation using programmatic workflows.
• Create production documentation, build records, powder reuse tracking, and traceability systems.
• Scope, install, commission, operate, and support equipment while training technicians and engineers.

Requirements

• Bachelor’s, master’s, or PhD in engineering focused on materials, manufacturing, or additive manufacturing.
• Typically 5+ years of LPBF process or applications development experience on real programs.
• Hands-on experience loading powder, setting up and monitoring builds, and debugging failure modes.
• Experience owning process development, designing DOEs, developing parameters, and closing failure modes.
• Working knowledge of build-preparation software such as Dyndrite, Magics, 3DXpert, EOSPrint, or Netfabb.
• Programming experience, preferably Python, together with strong documentation and traceability practices.

Nice to have

• Experience with high-gamma-prime nickel superalloys, high-preheat LPBF platforms, or reactive metals.
• Materials evaluation experience including metallography, SEM, mechanical testing, fractography, and powder characterization.
• Exposure to qualification programs, allowables, MMPDS or CMH-17 concepts, and statistical material-data analysis.
• Experience transferring processes from R&D into regulated production environments such as AS9100.
• Startup or prototype-pace experience.

Culture & Benefits

• Hands-on laboratory environment where engineers and technicians build, document, and troubleshoot together.
• Work on advanced LPBF equipment and engine parts made from highly challenging alloys.
• Flexible PTO, potential long-term incentives or equity, and additional employee benefits.
• Applications are accepted on an ongoing basis.