Processing Engineer III, Additive Manufacturing
Confirmed on the employer's own hiring board on Oct 13, 2026. First seen by Alion on Sep 28, 2026.
About the Role
We are looking for an engineer with deep metallurgical expertise to help build and lead a critical part of our additive manufacturing program. This is a hands-on technical role with real ownership - you will stand up and run our metallurgical test lab, lead process and material qualification across multiple alloy systems, and help set the technical direction for how we approach additive manufacturing quality. If you are someone who solves hard problems, follows through on what you commit to, and takes pride in building things that work - this role is worth a look.
What You'll Do
Build and run our metallurgical test lab. You will take our test lab from concept to full operation - selecting and qualifying equipment, establishing procedures, setting calibration schedules, and training the team on how to use it. Testing capabilities will include particle size distribution, porosity characterization, mechanical testing, and microstructural analysis. You will also have input to lab's long-term capability roadmap, keeping an eye on emerging technologies and methods.
Lead process and material qualification. You will develop and execute qualification procedures for stainless steel, nickel, titanium, and aluminum alloys to both customer and industry standards (AMS, ASTM, SAE, and others). This includes leading IQ/OQ/PQ activities for AM equipment, running structured experiments and DOE-based studies to validate process windows, and performing root-cause analysis when things go wrong. You will manage multiple qualification projects simultaneously and deliver on your commitments.
Work across teams. You will connect the dots across engineering, quality, and operations - bringing people together to solve problems, share knowledge, and keep AM initiatives moving forward. You will govern build and validation documentation standards in ProShop ERP, and help develop structured training.
Innovate. You will find better ways to qualify additively manufactured parts and build processes that expand what our team can do. This means work that shapes industry practice, not just internal practice.
What We're Looking For
We are open to a range of educational backgrounds - what matters most is what you have done and the impact you have made.
12+ years (H.S. Diploma) | 10+ years (A.A.) | 5+ years (Bachelor's) | 3+ years (Master's) | Ph.D.
A bachelor's or master’s in metallurgical engineering, materials science, or a closely related field is preferred.
Your experience should include expert-level metallurgical and materials testing, hands-on process qualification on metal AM platforms (laser powder bed fusion, DED, or binder jetting), and direct experience with stainless, nickel, titanium, and aluminum alloy systems.
Experience standing up or operating a metallurgical lab and leading IQ/OQ/PQ activities in a regulated environment (aerospace, medical device, or similar) is strongly preferred.
Expert-level knowledge of metallurgical testing: PSD, porosity, mechanical testing, and microstructural analysis
Hands-on experience with metal AM process and material qualification to AMS, ASTM, or SAE standards
Proficiency with advanced metrology instruments and quality systems
Strong DOE and statistical process control skills
Deep understanding of metallurgical principles - phase transformations, solidification behavior, defect formation - as they apply to AM alloy systems
Strong technical writing skills; able to produce qualification procedures and test reports that hold up to internal and customer review
Experience contributing to external technical forums, publications, or industry groups is an asset
Who You Are
You deliver on complex, high-stakes commitments with reliability, even under time pressure
You communicate clearly with both technical and non-technical audiences
You mentor others and invest in building the team's capability
You stay current on new technologies and bring what you learn back in practical ways
You design quality and safety into work from the start, not as an afterthought
Job Type: On-Site
Job Location: Woburn, MA. At this time, we are only considering applicants within a 100-mile radius. No relocation assistance provided.
About Rennscot MFG
Rennscot MFG, founded in 2017, started as a motorsports-focused shop in the aftermarket automotive industry. Now, they are a leading provider of advanced manufacturing services located in Woburn, MA. Rennscot MFG strives to be more than just a machine shop; they solve problems in innovative ways, using a suite of integrated services to fuel a passion for ideation. With a focus on diversifying into commercial and critical technology sectors, Rennscot MFG delivers cutting-edge technologies and unwavering commitment to quality. They offer a comprehensive range of services, including reverse engineering, metal & polymer additive manufacturing, and precision machining to support various industries’ needs. For more information, visit rennscotmfg.com.
ITAR Requirement
To conform to US Government export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a US citizen, lawful permanent resident of the US, protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the US Department of State. Learn more about the ITAR here: https://www.pmddtc.state.gov/ddtc_public/ddtc_public?id=ddtc_public_portal_itar_landing.
EEO Statement
Rennscot MFG is an Equal Opportunity Employer; employment with Rennscot MFG is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.
It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.