Manufacturing Design Engineer - Powder Materials & Atomization Process
Confirmed on the employer's own hiring board on Nov 8, 2026. First seen by Alion on Jun 24, 2026. Apple scores A on the Alion truth index.
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Description
The Apple Manufacturing Design Materials Process Engineer is accountable for leading the development, qualification, and high-volume deployment of advanced metal powder manufacturing processes across Apple’s worldwide supply base. In this critical, hands-on role, you will specialize in Aluminum (Al) and Titanium (Ti) powder synthesis, gas atomization, powder characterization, and recycling pipelines destined for additive manufacturing process.
You will collaborate directly with Apple cross functional teams, as well as our international powder suppliers. You are empowered and expected to bring deep metallurgical creativity, process rigor, and data-driven problem solving to pioneer sustainable, high-yield powder supply chains for Apple products.
Minimum Qualifications
BS, MS, or PhD in Materials Science and Engineering, Metallurgical Engineering, Mechanical Engineering, or a related discipline. Advanced degree preferred.
Hands-on experience in metal atomization, powder metallurgy, materials characterization, and manufacturing process engineering with a strong emphasis on Titanium and Aluminum alloys.
Preferred Qualifications
Deep industry expertise in gas atomization technologies (e.g., Vacuum Induction Gas Atomization [VIGA], Electrode Induction-melting Gas Atomization [EIGA]).
Comprehensive knowledge of powder lifecycle & post-processing, including inert classification, sieving, air classification/cyclone separation, blending, degasification, and safe handling/passivation of reactive metal powders.
Expertise in powder characterization methodologies and standards (ASTM/ISO) covering:
Particle Size Distribution (PSD via laser diffraction, dynamic image analysis).
Powder morphology (SEM, circularity, sphericity, satellites, internal porosity via micro-CT/cross-sectioning).
Rheology and flowability (Hall/Carney flowmeter, Freeman FT4 powder rheology, tap/apparent density).
Interstitial and trace chemistry control ($O, N, H, C, S$ via inert gas fusion / LECO; ICP-OES/MS for alloy constituents).
Strong background in circular metallurgy and sustainable feedstocks, including re-atomization of manufacturing scrap/swarf, powder rejuvenation/reuse loops, and minimizing carbon footprint to support Apple’s 2030 carbon neutrality goals.
Demonstrated mastery of Design of Experiments (DOE), Statistical Process Control (SPC), Gauge R&R, and data-driven process optimization.
Practical understanding of downstream interactions-how powder characteristics (interstitial oxygen pick-up, PSD skewness, flowability) directly influence build density, mechanical properties, and final cosmetic anodization/polishing yields.
Robust project management skills with the ability to lead technical initiatives and manage schedules independently across global time zones.
Comfort and proficiency working on the production floor at partner atomization plants and test laboratories worldwide.