Sr. Manufacturing Engineer, Inconel
$99,584–$136,929 year
On-siteDevens, Massachusetts, United States
Job Summary
Develop, qualify, and optimize Inconel laser powder bed fusion manufacturing processes to improve safety, quality, throughput, and cost. Own process development from initial print parameter development through production release, while supporting daily production by troubleshooting print failures and process variation. Analyze manufacturing data to identify trends, improve process capability, and reduce variability using statistical methods and DOE techniques. Develop, validate, and maintain standard operating procedures, work instructions, process documentation, and manufacturing specifications. Lead root cause investigations for quality escapes, build failures, scrap, and process deviations while implementing sustainable corrective actions. Mentor technicians and manufacturing personnel on best practices for LPBF process execution and equipment operation. Maintain compliance with safety, quality, and regulatory requirements while promoting operational excellence. Work cross-functionally with Production, Quality, Supply Chain, and Manufacturing Engineering to support new product introduction and production scale-up.
Required Qualifications
- 5+ years of manufacturing engineering experience within metal additive manufacturing, precision manufacturing, aerospace, or other high-volume manufacturing environments.
- Experience supporting laser powder bed fusion (LPBF), metal additive manufacturing, CNC machining, or similarly complex manufacturing processes.
- Strong understanding of process development, statistical process control, root cause analysis, and continuous improvement methodologies.
- Experience creating manufacturing documentation including work instructions, process specifications, and engineering standards.
- Demonstrated ability to troubleshoot complex manufacturing issues in a production environment.
- Excellent communication and cross-functional collaboration skills.
- Must be a U.S. Person due to export-controlled technologies.
Desired Qualifications
- Experience developing manufacturing processes for Inconel or other nickel-based superalloys.
- Knowledge of metallurgy, heat treatment, residual stress management, and defect mechanisms associated with LPBF manufacturing.
- Experience with process validation, DOE, PFMEA, SPC, and Six Sigma methodologies.
- Familiarity with MES, ERP, and manufacturing data collection systems.
- Experience supporting high-volume production environments and new product introductions.
- Lean Manufacturing and continuous improvement experience.
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