Additive Manufacturing Engineer
$87,100–$157,450 year
On-site · Huntsville, Alabama, United States
Job Summary
Additive Manufacturing Engineer at Leidos Defense Systems to support the Advanced Materials Department in Huntsville, AL. Responsibilities include design for additive manufacturing (DfAM), planning layouts for AM equipment and capabilities, serving as the resident AM expert across multiple metal AM technologies, and conducting AM analyses (cost, feasibility, deformation, and material/component properties). Requires on-site presence in Huntsville with hands-on metal AM experience, proficiency with relevant software tools, familiarity with high-strength alloys, and broad experience in CAD, post-processing, simulations, and vendor coordination.
Required Qualifications
- Bachelor's degree in mechanical engineering, materials science, manufacturing engineering, or related field from ABET-accredited university with minimum 3.2 GPA
- 4+ years of experience in metal additive manufacturing or MS with 2+ years or PhD with 1+ years
- Hands-on experience with metal additive manufacturing engineering
- Experience with design for additive manufacturing (DfAM), especially Powder Bed Fusion, DED, and/or Cold Spray
- Experience with metal AM support structure design
- Experience setting up metal builds with software such as Materialise Magics, Oqton, 3DXpert, EOSPrint
- Ability to support hardware systems including setup, operation, and troubleshooting of AM equipment
- Familiar with high strength/temperature metal alloys (nickels, HEAs, refractories)
- Design experience in SolidWorks, Creo, or similar CAD
- Experience with post-processing methods including heat treatment, machining, and surface finishing
- Experience with simulation tools for additive manufacturing (thermal, distortion, support optimization)
- Experience communicating with external vendors or contract manufacturers
- Experience obtaining quotes for work and equipment
- Experience writing proposals and SOPs
- Hazardous materials handling experience
- Safety awareness and ability to train others
- On-site work in Huntsville, AL or willingness to relocate
- Excellent collaboration across program teams and departments
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