Principal Process Engineer, LPBF

Beehive Industries is dedicated to Powering American Defenseby revolutionizing the design, development, and delivery of jet propulsion systems to support the warfighter. Through the integration of additive manufacturing, the company aims to meet the growing and urgent needs for unmanned aerial defense by dramatically improving a jet engine’s speed to market, fuel efficiency, and cost.

Founded in 2020, the company is headquartered in Centennial, Colorado, with additional facilities in Knoxville, Tennessee, Loveland Ohio, and Mount Vernon, Ohio. Beehive is committed to grow and advance the defense industrial base while manufacturing exclusively in the USA. This role will be located at our Knoxville, Tennessee facility.

Role Overview

The Principal Additive Process Manufacturing Engineer serves as a recognized technical authority responsible for advancing Laser Powder Bed Fusion (LPBF) technology, materials, and production capabilities for critical aerospace and defense applications. This role provides expert-level leadership in additive manufacturing process development, metallurgy, and production scale-up while influencing technical strategy and manufacturing innovation. The Principal Additive Process Manufacturing Engineer drives solutions to complex technical challenges and establishes best practices that enable reliable, high-performance additive manufacturing operations.

What You’ll Do...

• Serve as a technical authority for LPBF additive manufacturing processes, materials development, and production readiness initiatives
• Define technical strategies and roadmaps for additive manufacturing capabilities, process optimization, and production scalability
• Lead development and implementation of advanced LPBF process parameters for complex materials and geometries
• Establish and improve additive manufacturing standards, specifications, process controls, and technical documentation
• Drive resolution of the most complex challenges related to powder metallurgy, laser-material interaction, melt pool behavior, thermal management, and part performance
• Lead development of production-ready additive manufacturing processes including qualification, validation, and continuous improvement activities
• Apply advanced expertise in metallurgy and additive manufacturing to optimize material properties, defect reduction, and manufacturing performance
• Influence integration of LPBF into broader manufacturing workflows including post-processing, machining, inspection, and quality systems
• Guide cross-functional engineering teams in solving complex technical problems and advancing additive manufacturing capabilities
• Mentor engineers and provide technical leadership across additive manufacturing initiatives
• Support strategic decisions related to equipment capabilities, process improvements, and future manufacturing technologies
• Represent additive manufacturing expertise in technical reviews with leadership, customers, suppliers, and industry partners
• Perform other duties as assigned

You have...

Education

• Bachelor’s degree in Engineering, Metallurgy, Materials Engineering, Mechanical Engineering, or a related technical field; or equivalent combination of education and experience

Experience

• Minimum of 12 years of experience in additive manufacturing, LPBF process development, metallurgy, materials engineering, or related manufacturing disciplines
• Extensive experience developing, optimizing, and scaling additive manufacturing processes for production applications
• Demonstrated experience serving as a technical leader on complex engineering programs and manufacturing initiatives
• Experience supporting aerospace, defense, or other highly regulated manufacturing environments

Skills & Competencies

• Expert knowledge of LPBF systems, additive manufacturing processes, and production implementation strategies
• Deep understanding of powder metallurgy, material behavior, laser-material interactions, melt pool dynamics, and thermal management
• Advanced experience with process parameter development, powder characterization, defect analysis, and process optimization
• Ability to establish technical direction and solve complex engineering challenges with significant organizational impact
• Experience developing manufacturing standards, process specifications, and qualification strategies
• Strong understanding of process control, experimental design (DOE), data analysis, and manufacturing validation methods
• Ability to influence cross-functional teams and communicate complex technical concepts to technical and executive audiences
• Demonstrated ability to mentor engineers and elevate technical capabilities within an organization
• The ability to obtain and maintain a U.S. government issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance

Nice to have...

• Master’s degree or PhD in Engineering, Metallurgy, Materials Engineering, or related field
• Experience leading production LPBF implementation for aerospace or defense applications
• Expertise in laser optics, sensors, in-situ monitoring, and additive manufacturing process control systems
• Experience with additional additive manufacturing technologies including EBM, DED, or binder jet
• Familiarity with investment casting, machining, and hybrid manufacturing strategies
• Experience leading additive manufacturing technology transitions from research and development through production scale-up
• Experience contributing to patents, publications, technical presentations, or industry standards
• Experience influencing manufacturing strategy, capital investments, and long-term technology roadmaps

If this sounds like you, please submit an application with your resume. This could be the opportunity you are looking for to expand your skills, contribute to a winning team, and work with talented people who love what they do and take pride in our mission.

Beehive Industries offers a comprehensive benefits package that includes group Medical, Dental, Life, and Short and Long-Term disability coverage from day one. We also offer a generous 401(k) Retirement Savings Plan with a Company match. Every role at Beehive Industries is bonus eligible and will also receive equity in the company.

Beehive Industries is committed to full compliance with applicable anti-discrimination laws. We are an equal opportunity employer and value diversity at our company. We strive to create an inclusive work environment and will not discriminate on the basis of race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status.