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Step into the world of metal additive manufacturing for the KARNO generator, where advanced laser powder-bed fusion meets real engineering challenge. Engineers in this group work across machine behavior, process optimization, material performance, data analytics, and hardware development to ensure high-quality, repeatable production using metal laser powder-bed fusion systems. In this role, you’ll move across the entire additive manufacturing ecosystem. You’ll investigate how machine settings influence melt pools, porosity, and microstructure, and you’ll design controlled experiments to refine parameters and boost repeatability. A big part of the job involves troubleshooting machine quirks, interpreting sensor data, and making sense of real-time process feedback. You’ll also be working closely with design, materials, and hardware teams to bring complex AM components from early prototypes into reliable production. Along the way, you’ll help build the systems, standards, and workflows that turn metal AM into a high-trust, high-reliability manufacturing process for power-generation hardware.
Job Responsibility:
Identify and optimize critical-to-function (CTF) parameters that drive mechanical performance, density, porosity, microstructure, and repeatability
Design and execute experiments (DOE) to map the process window, understand sensitivities, and reduce variation
Build and maintain parameter sets for new alloys, new hardware, and new machine configurations
Work with sensor data, log files, and monitoring systems to correlate in-process signatures with part quality
Develop statistical models, SPC controls, and trend analysis tools to ensure stable production behavior
Improve AM machine capability through hardware tuning, sensor integration, calibration routines, and control-system optimization
Lead machine troubleshooting, repair activities, and upgrades to improve uptime, repeatability, and print speeds
Conduct machine characterization using advanced tools and metrology equipment to map laser optics, powder behavior, thermal gradients, and recoater performance
Support machine-level IQ/OQ/MQ qualification and ongoing PM/maintenance strategies
Collaborate with equipment vendors and internal engineering teams on new machine features, experimental setups, and pilot systems
Drive automation, digital manufacturing, and data-acquisition improvements for machine performance monitoring
Requirements:
Bachelor’s degree in mechanical, materials science, aerospace, or related engineering discipline
Minimum of 5 years of engineering experience after earning a bachelor’s degree
Direct, hands-on experience with laser powder bed fusion (LPBF) additive manufacturing REQUIRED
Background in fabrication, prototyping, testing, or process development within an engineering environment
Ability to interpret engineering drawings, apply GD&T, and understand material properties data
Strong analytical and root-cause problem-solving skills
Comfortable working hands-on with machines, tools, test equipment, and mechanical assemblies
Nice to have:
Build prep/simulation software like ANSYS Additive Suite, 3DXpert, or Dyndrite
Experience developing AM parameters, designing DOEs, or using statistical analysis tools (SPC, JMP, Minitab, Python, MATLAB)
Experience troubleshooting AM machines, calibrating optics, repairing systems, or working with machine sensors and controls
Knowledge of DFAM principles, heat-treat processes, and additive-appropriate material behaviors (e.g., nickel alloys, titanium)
Familiarity with CAD tools (NX, SolidWorks, or similar) and simulation/analysis workflows
Experience with IQ/OQ/MQ qualification approaches
Strong communication skills and ability to present findings to cross-functional teams
Experience in a fast-paced R&D or startup hardware environment
What we offer:
Medical Plans, with PPO or HDHP options
Dental Plans, with buy-up option
Vision Plan
Life Insurance and Accidental Death & Dismemberment Plans, with buy-up options